Conveyor system assembly

ABSTRACT

In an aspect, a wear plate for use with a conveyor system is provided. The wear plate has a plate mount, having a fastener retainer having a retention hole extending through the wear plate, and a retainer support being defined by at least one cut in the wear plate adjacent to and at least partially defining the fastener retainer, the retainer support connecting the fastener retainer to a main portion of the wear plate and enabling the fastener support to be depressed relative to a top surface of the wear plate.

FIELD

The present disclosure relates to the field of conveyor systems fortransporting wheeled structures, and in particular to a conveyor systemassembly suitable for use in an automatic vehicle wash station.

BACKGROUND OF THE DISCLOSURE

Conveyor systems have long been used to assist in the transport ofmaterials from one location to another, in particular with respect toheavy and cumbersome items. The use of conveyor systems in assemblylines is well documented, with perhaps Henry Ford being the most famousproponent of the technology of the 20^(th) century.

Conveyors come in a variety of configurations, suiting a wide array ofimplementations. Belt conveyors in particular have been widely adopteddue to their wide versatility and adaptability. For example, beltconveyors are commonly used in the warehousing, manufacturing, andmining sectors. More recently, belt conveyors have found application inthe automotive industry, in particular with respect to automated carwash stations.

The installation and maintenance of such conveyor systems istime-consuming and, thus, costly. As such conveyor systems include alarge number of parts that are manufactured in one or more locations andassembled on site, it is desirable to facilitate the assembly process.Further, due to the high cost of downtime, it is desirable to prolongthe life of the parts and facilitate their replacement prior to abreakdown of the conveyor system.

SUMMARY OF THE DISCLOSURE

According to an aspect, there is provided a wear plate for use with aconveyor system, comprising: a plate mount, having a fastener retainerhaving a retention hole extending through the wear plate; and a retainersupport being defined by at least one cut in the wear plate adjacent toand at least partially defining the fastener retainer, the retainersupport connecting the fastener retainer to a main portion of the wearplate and enabling the fastener support to be depressed relative to atop surface of the wear plate.

The fastener retainer can be depressed via machine prior to installationof the wear plate.

The fastener retainer can be depressable during tightening of a fastenerinserted into the retention hole and engaging a nut. The at least onecut can extend circumvolutely from the fastener retainer.

According to another aspect, there is provided a wear plate structurefor use with a conveyor system, comprising: a wear plate, at least apart of which is constructed from a first material having a firstelectrical conductivity, wherein the wear plate has a wear surface thatis positioned to incur wear and an undersurface opposite the wearsurface; and a first electrical conduit and a second electrical conduitwhich extend from the wear plate, wherein, when the first and secondelectrical conduits are connected to a voltage source, a first currentflows between the first electrical conduit and the second electricalconduit through the first material when the wear plate is in a firstwear condition, and current flow is reduced from the first current flowbetween the first electrical conduit and the second electrical conduitthrough the first material when the wear plate is in a second wearcondition.

The current flow can be reduced to zero between the first electricalconduit and the second electrical conduit when the wear plate is in thesecond wear condition. The wear plate can have a gap in the firstmaterial of the wear plate so that the first electrical conduit and thesecond electrical conduit are unconnected by the first material when thewear plate is in the second wear condition. A second material can atleast partially fill the gap in the first material, the second materialhaving a second electrical conductivity that is lower than the firstelectrical conductivity.

According to a further aspect, there is provided a drive coupler,comprising: a first connector coupleable to a first drive member fortorque transfer therebetween, the first drive member rotating about afirst axis, the first connector having a first connector face; aspherical bearing positioned in the first connector for receiving asecond drive member that is rotatable about a second axis, the sphericalbearing being positioned at the intersection of the first and secondaxes; a second connector having a second connector face, and beingrotationally coupleable to the first connector for torque transfertherebetween, wherein the second connector is coupleable to the seconddrive member for torque transfer therebetween; and a compressible spacerpositioned between the first connector face and the second connectorface, thereby permitting the first and second connector faces to benon-parallel to one another.

The first drive member can be connected to a source of torque and thesecond drive member can be connected to a load.

An end portion of the second drive member can have a non-circularcross-sectional shape, and a plurality of circumferentially extendingslots thereon, the drive coupler can further comprise a locking flangethat has a pass-through aperture having a profile that permits thelocking flange to be slidable axially along the end portion of thesecond drive member when the locking flange is in a first rotationalposition about the second axis, and can be rotatable from the firstrotational position to a second rotational position about the secondaxis to engage the plurality of circumferentially extending slotsthereby axially locking the locking flange with the second drive member,wherein the locking flange is connectable to the second connector.

According to yet another aspect, there is provided a return rollerassembly for use with a conveyor system, comprising: a shaft defining anaxis and having a first shaft end and a second shaft end; a bearingmember rotatably mounted on the shaft, and having a central bearingmember portion upon which is mounted a roller wheel for rotatablysupporting a lower return portion of a conveyor belt, a first lateralbearing member portion extending axially from the central bearing memberportion towards the first shaft end, and a second lateral bearing memberportion extending axially from the central bearing member portiontowards the second shaft end; a first bearing member sleeve structureextending from the bearing member towards the first shaft end, whereinthe first bearing member sleeve structure is sealingly mounted to thefirst lateral bearing member portion, wherein the first sleeve has ashaft engagement surface that is rotatably engaged with the shaft; asecond bearing member sleeve structure extending from the bearing membertowards the second shaft end, wherein the second bearing member sleevestructure is sealingly mounted to the second lateral bearing memberportion; and a first shaft sleeve structure fixedly and sealinglymounted to the shaft laterally outboard towards the first shaft endrelative to the shaft engagement surface of the first bearing membersleeve structure, wherein the first bearing member sleeve structure hasa first rotation interface sealing surface and the first shaft sleevestructure has a second rotation interface sealing surface, wherein thefirst and second rotation interface sealing surfaces extend radially andcircumferentially and engage one another to seal against migration ofcontaminants therebetween, and wherein the shaft sleeve structure urgesthe first and second rotation interface sealing surfaces into engagementwith one another.

The first bearing member sleeve structure can be mounted to the firstlateral bearing member portion with a first bearing member sleevestructure sealing member therebetween so as to provide sealingengagement therebetween, and the first shaft sleeve structure can besealingly mounted to the shaft with a first shaft sleeve structuresealing member therebetween so as to provide sealing engagementtherebetween.

The first shaft sleeve structure can be fixedly mounted to the shaft viaa first shaft sleeve mounting pin that passes through the first shaftsleeve and the shaft.

The bearing member and the roller wheel can be a first bearing memberand a first roller wheel respectively, and the return roller assemblycan further include a second bearing member rotatably mounted on theshaft, closer to the second shaft end than is the first bearing member,and having a central bearing member portion upon which is mounted asecond roller wheel for rotatably supporting the conveyor belt, a firstlateral bearing member portion extending axially from the centralbearing member portion towards the second shaft end, and a secondlateral bearing member portion extending axially from the centralbearing member portion towards the first shaft end, wherein the returnroller assembly further includes a first bearing member sleeve structurefor the second bearing member, extending from the second bearing membertowards the second end, and sealingly mounted to the first lateralbearing member portion of the second bearing member, and having a shaftengagement surface that is rotatably engaged with the shaft, and whereinthe return roller assembly further includes a second bearing membersleeve structure for the second bearing member, extending from thesecond bearing member towards the first shaft end, wherein the secondbearing member sleeve structure for the second bearing member issealingly mounted to the second lateral bearing member portion of thesecond bearing member, and wherein the return roller assembly furtherincludes a second shaft sleeve structure fixedly and sealingly mountedto the shaft laterally outboard towards the second shaft end relative tothe shaft engagement surface of the first bearing member sleevestructure of the second bearing member, and wherein the first bearingmember sleeve structure for the second bearing member has a firstrotation interface sealing surface and the second shaft sleeve structurehas a second rotation interface sealing surface, wherein the first andsecond rotation interface sealing surfaces on the first bearing membersleeve structure for the second bearing member and the second shaftsleeve structure extend radially and circumferentially and engage oneanother to seal against migration of contaminants therebetween, andwherein the second shaft sleeve structure urges the first and secondrotation interface sealing surfaces into engagement with one another.

The first bearing member sleeve structure can include a laterally outerportion and a laterally inner portion, wherein the laterally outerportion has a greater inner diameter than does the laterally innerportion and overlaps axially with the first shaft sleeve structure andis spaced radially from the first shaft sleeve structure.

According to still yet another aspect, there is provided a debrisdeflector kit for use with a conveyor system, comprising: a debrisdeflector configured to deflect debris that is falling from a conveyorbelt towards an elimination end thereof, the debris deflector beingcoupleable towards a first end thereof to a first lateral frame portion;and a first mounting bracket engaging the debris deflector towards asecond end thereof opposite the first end of the debris deflector via afirst projection of one of the debris deflector and the first mountingbracket that is insertable through a first aperture in another of thedebris deflector and the first mounting bracket, the first mountingbracket being coupleable to a second lateral frame portion spaced fromthe first lateral frame portion.

The debris deflector can be securable to the first mounting bracket viabending of the projection extending out of the aperture.

The debris deflector can be coupleable to the first lateral frameportion via a second mounting bracket engaging the debris deflector atthe first end thereof via a second projection of one of the debrisdeflector and the second mounting bracket that is insertable through asecond aperture in another of the debris deflector and the secondmounting bracket, the second mounting bracket being coupleable to thefirst lateral frame portion. The first mounting bracket and the secondmounting bracket can each have one of the first projection and the firstaperture at a first position thereon and one of the second projectionand the second aperture at a second position thereon. The firstprojection and the second projection can be tabs and the first apertureand the second aperture can be slots.

The first mounting bracket and the second lateral frame portion can havefeatures enabling the first mounting bracket to slidingly engage thesecond lateral frame portion.

According to another aspect, there is provided a return roller kit foruse with a conveyor system, comprising: a return roller assembly havinga rotation axis about which rotates at least one roller wheel forsupporting a conveyor belt along a return path, the return rollerassembly having a first orientation retention feature in a first endthereof.

The first orientation retention feature can include a projectionextending orthogonal to the rotation axis. The projection can be a firstpin inserted through through-holes in the first end of the return rollerassembly.

The return roller kit can further include a first mounting brackethaving a first aperture and a first ledge adjacent to the first aperturefor supporting the first end of the return roller assembly.

The first orientation retention feature can include a first pin insertedthrough through-holes in the first end of the return roller assembly,the return roller kit can further include a first mounting brackethaving a first aperture and a first ledge adjacent to the first aperturefor supporting the first end of the return roller assembly, the firstledge having a first pin-hole for receiving the first pin of the returnroller assembly.

The return roller assembly can have a second orientation retentionfeature in the second end thereof.

The return roller assembly can have a second irregularity in the secondend thereof.

The return roller assembly can have a second pin inserted throughthrough-holes in the second end of the return roller assembly.

The return roller assembly can have a second pin inserted throughthrough-holes in a second end of the return roller assembly, and thereturn roller kit can further include a second mounting bracket having asecond aperture and a second ledge adjacent to the second aperture forsupporting the second end of the return roller assembly, the secondledge having a second pin-hole for receiving the second pin of thereturn roller assembly.

According to still yet another aspect, there is provided a drive couplerassembly, comprising: a first drive member that is supported forrotation about a first axis by at least a first bearing and a secondbearing for the first drive member; a second drive member that has afirst end that is proximal to the first drive member and a second endthat is distal to the first drive member, wherein the second end issupported by a first bearing for the second drive member; a firstconnector coupled to the first drive member for transfer of torquetherebetween, the first connector having a first connector face; aspherical bearing positioned in the first connector for receiving thefirst end of the second drive member for rotation of the second drivemember about a second axis, the spherical bearing being positioned atthe intersection of the first and second axes; a second connector havinga second connector face, and being rotationally coupleable to the firstconnector for transmission of torque therebetween, wherein the secondconnector is coupleable to the second drive member for transfer oftorque therebetween; and a compressible spacer positioned between thefirst connector face and the second connector face, thereby permittingthe first and second connector faces to be non-parallel to one another.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the disclosure willbe apparent from the following description of embodiments hereof asillustrated in the accompanying drawing. The accompanying drawings,which are incorporated herein and form a part of the specification,further serve to explain the principles of the disclosure and to enablea person skilled in the pertinent art to make and use the disclosure.The drawings are not to scale.

FIG. 1 is a plan view of the conveyor system according to an embodimenthereof;

FIG. 2a is a partial side sectional view of the conveyor systemaccording to the embodiment of FIG. 1;

FIG. 2b is a partial side sectional view of the conveyor system withreference to line 2 b-2 b of FIG. 2 a;

FIG. 2c is a partial side sectional view of the conveyor system withreference to line 2 c-2 c of FIG. 2 a;

FIG. 3a is a partial isometric view of the conveyor system according tothe embodiment of FIG. 1, highlighting features of the conveyor frame;

FIG. 3b is a partial isometric view of the conveyor system withreference to line 3 b-3 b of FIG. 3 a;

FIG. 4 is a partial transverse sectional view of the conveyor systemaccording to FIG. 1, highlighting features in the region of the endlessbelt;

FIG. 5 is a partial transverse section view of the conveyor systemaccording to FIG. 1, showing an alternative embodiment of the debrisdeflector;

FIG. 6 is a partial isometric of the debris deflector according to theembodiment of FIG. 5;

FIG. 7 is a partial isometric view of the conveyor system according toFIG. 1, showing the use of lateral guides on the idler end;

FIG. 8 is an enlarged isometric view of the lateral guide according tothe embodiment of FIG. 7;

FIG. 9 is a partial isometric view of the conveyor system according toFIG. 1, detailing features of the mount brackets;

FIG. 10 is a partial isometric view of the conveyor system according toFIG. 1, detailing features of the wear plates;

FIG. 11 is a partial plan view of the conveyor system according to FIG.1, detailing features of the wear plates;

FIG. 12a is a sectional view of one of the wear plates with reference toline 12 a-12 a of FIG. 11, showing features of the debris slot;

FIG. 12b is a sectional view of one of the wear plates with reference toline 12 b-12 b of FIG. 12a , showing features of the debris slot;

FIG. 13 is an enlarged sectional view of the guide member;

FIG. 14 is a partial sectional view of the guide member with referenceto line 15-15 of FIG. 13, detailing features of the roller andthermoplastic bushing;

FIG. 15 is a partial sectional view of the guide member with referenceto line 14-14 of FIG. 13, detailing features of a first end thereof;

FIG. 16 is an enlarged front view of an alternate embodiment of theguide member, showing the use of side rollers;

FIGS. 17a -20 show a rinsing system for the conveyor system;

FIGS. 21-25 show a flooding system for the conveyor system;

FIGS. 26a-26c show wear plates according to an alternative embodiment;

FIGS. 27a and 27b show wear plates according to other alternativeembodiments;

FIG. 28 shows the mating features of edge guides and wear platesaccording to an alternative embodiment;

FIGS. 29a and 29b are top perspective views of a debris deflector for aconveyor system in accordance with another embodiment;

FIG. 30a is a top perspective view of a lateral bracket support of theconveyor system of FIGS. 29a and 29 b;

FIG. 30b is a partial isometric view of bracket support slots of thelateral bracket support with reference to line 30 b-30 b of FIG. 30 a;

FIGS. 31a and 31b are isometric views of sides of a mounting bracket foruse with the lateral bracket support of FIGS. 30a and 30 b;

FIGS. 32a to 32f show the connecting and securing of the mountingbracket of

FIGS. 31a and 31b to the lateral bracket support of FIGS. 30a and 30 b;

FIGS. 33a to 33e show the installation of the debris deflector of FIGS.29a and 29b between two mounting brackets secured to the lateral bracketsupports as shown in FIGS. 32a to 32 f;

FIG. 34 shows a debris deflector in accordance with a furtherembodiment;

FIG. 35a is an isometric view of a belt return roller assembly for usewith the mounting brackets of FIGS. 31a and 31 b;

FIG. 35b is an isometric section view of the belt return roller assemblyof FIG. 35 a;

FIG. 35c shows a partial section view of the belt return roller assemblyof FIG. 35 a;

FIGS. 36a and 36b show the installation of the belt return rollerassembly of FIG. 35a between two mounting brackets of FIGS. 31a and 31b;

FIGS. 37a and 37b show a wear plate for a conveyor system in accordancewith another embodiment having a laser-cut plate mount;

FIGS. 38a and 38b show the wear plate of FIGS. 37a and 37b afterdepression of the plate mount;

FIG. 39 shows a bolt inserted through the depressed plate mount of FIGS.38a and 39 b;

FIG. 40 shows a wear plate anchor for use with the wear plate of FIGS.39a and 39 b;

FIGS. 41a to 41d show the securing of the wear plate of FIGS. 39a and39b to a support deck using the plate anchor of FIG. 40;

FIG. 42a shows a wear plate for use with a conveyor system in accordancewith another embodiment;

FIG. 42b is an isometric view of a plate mount of the wear plate of FIG.42a shown in isolation prior to being secured to a grid panel;

FIG. 42c is a partial section view of the wear plate of FIGS. 42a and42b secured to the wear plate anchor of FIG. 40 via a bolt prior totightening of the bolt;

FIG. 42d is an isometric view of the plate mount of the wear plate ofFIGS. 42a to 42c shown in isolation after tightening of the bolt shownin FIG. 42c ;

FIG. 42e is a partial section view of the wear plate of FIGS. 42a to 42csecured to the wear plate anchor of FIG. 40 via a bolt after tighteningof the bolt shown in FIG. 42 c;

FIG. 43a is a plan view of a partial belt drive assembly;

FIG. 43b is an isometric view of a drive coupler in accordance with anembodiment connecting the drive motor to a portion of the drive shaft ofFIG. 43a and a set of sprockets mounted on the drive shaft for drivingan endless belt;

FIG. 43c is an isometric view of a slotted sleeve of the transmission ofFIG. 43a that couples to the drive coupler of FIGS. 43a and 43 b;

FIG. 44a is an isometric view of the drive coupler of FIG. 43 b;

FIG. 44b is a section view of the drive coupler of FIG. 44 a;

FIG. 45 is an exploded view of various components of the drive couplerof FIGS. 44a and 44 b;

FIGS. 46a to 46c show the coupling of the drive shaft of FIGS. 43a and43b to the drive coupler of FIGS. 44a and 44 b;

FIG. 47a is a top isometric view of a wear plate in accordance with afurther embodiment having a wear sensor;

FIG. 47b is a bottom isometric view of the wear plate of FIG. 47 a;

FIG. 47c shows electric wires coupled to sensor connectors on the bottomof the wear plate of FIGS. 47a and 47b ; and

FIGS. 48a and 48b are partial section views of the wear plate andelectric wires of FIGS. 47a to 47c showing the wear plate in a newcondition and a worn-out condition.

DETAILED DESCRIPTION

The following detailed description is merely exemplary in nature and isnot intended to limit the disclosure or the application and uses of thedisclosure. A person skilled in the relevant art will recognize thatother configurations and arrangements can be used without departing fromthe scope of the disclosure. Furthermore, there is no intention to bebound by any expressed or implied theory presented in the precedingtechnical field, background, brief summary, or the following detaileddescription.

Reference is made to FIG. 1, which shows a service line 10 having aconveyor system 20 for moving a wheeled structure 11, in accordance withan embodiment. As used herein, the term service line is not intended tobe restrictive, and may encompass for example an automatic vehicle washstation (e.g., for cars, commercial trucks, etc.), a manufacturing orassembly line (e.g., for cars, trucks, non-powered mobile units, etc.)as well as a repair or detailing station (e.g., for cars, trucks, etc.).In addition, the term wheeled structure is not intended to berestrictive, and may encompass for example powered landborne vehicles(e.g., trucks, automobiles, tractors, recreational vehicles, etc.),non-powered landborne mobile units (e.g., recreational trailers, utilitytrailers, etc.), and airborne vehicles (e.g., airplanes, etc.).

The conveyor system 20 is adapted to transport a wheeled structure alonga longitudinal length of the service line 10. As presented in FIG. 1,service line 10 is shown in the form of a car wash station having a washtunnel 22. Accordingly, the conveyor system 20 includes a service zone24 within the region of the wash tunnel 22 through which the vehicle istransported for a wash cycle. The conveyor system 20 also may alsoinclude a loading zone 26 adjacent a tunnel entrance 28, where vehiclesalign and initially load onto the conveyor system 20.

The conveyor system 20 is configured as a dual-belt system comprising apair of endless belts mounted in a longitudinal direction through theservice line 10. The endless belts 36 a, 36 b are positioned in paralleland spaced-apart relationship relative to one another through theloading and service zones 26, 24. In the region between the pair ofendless belts 36 a, 36 b, there may be positioned a central stationaryplatform 38 of removable panels that permit access to regions under thepair of endless belts 36 a, 36 b, in particular for servicing andmaintenance. It will be appreciated that where the conveyor system 20 isprovided with two or more endless belts to transport the wheeledstructure along the service line 10, the endless belts will move insynchronous motion. As the arrangement for each of the endless belts 36a, 36 b is substantially identical, the endless belts 36 a, 36 b areherein collectively referred to as the endless belt 36 unless otherwisespecified.

The endless belts 36 a, 36 b are made of a plurality of plastic beltsegments that are hingedly coupled via pins that are typically made ofmetal or plastic. The plastic of the belt segments has a hardness H_(BS)that enables the belt segments to withstand the load of a vehiclepositioned thereon.

Turning now to FIGS. 2a, 2b and 2c , the conveyor system 20 is generallysupported within a trench 40 having a depth suitable to house therequired drive and guide mechanisms, and to permit maneuverability toservice personnel. The endless belt 36 has an upper transport portion 42and a lower return portion 44, and extends along the conveyor system 20between a drive end 46 and an idler end 48. The drive end 46 and idlerend 48 provide axially elongated rollers 50 and 52, respectively, whichare rotatably supported on a conveyor frame 54, to guide the endlessbelt 36 around the respective drive and idler ends 46 and 48.

The drive end 46 includes a drive module 56 adapted to engage and movethe endless belt around the drive and idler ends 46 and 48. The drivemodule 56 may be an electric motor as shown, and may include at leastone drive member 58 to engage the endless belt 36 and move it around therespective drive and idler ends 46 and 48. As shown, the drive member 58is provided in the form of at least one sprocket 60 provided withsprocket teeth 62 to engage complementary tracks (not shown) on theinward surface 64 of the endless belt 36. The conveyor system 20 willadditionally include guide members 66 supported upon the conveyor frame54 to support the lower return portion 44 of the endless belt 36 as itmoves back towards the idler end 48 on the underside of the conveyorsystem 20. As shown, the guide members 66 are provided in the form ofrollers.

In motion, the upper transport portion 42 of the endless belt 36 movesin tension from the idler end 48 towards the drive end 46 by drivemember 58, while the lower return portion 44 moves in a slackened statefrom the drive end 46 towards the idler end 48.

Turning now to FIGS. 3a and 3b , shown is an enlarged view of theconveyor system 20 with the endless belt 36 and associated supportstructure removed to highlight features of the conveyor frame 54. Theconveyor frame 54 includes a plurality of cross-members 68 positionedtransversely relative to the longitudinal direction of the service line10. The cross-members 68 are dimensioned to span the width of the trench40, and are adapted to mount on opposing surfaces 70 and 72. Eachcross-member 68 also provides at least one footing 74 at approximately amidpoint thereof, extending to a floor 76 of the trench 40 to provideadditional load-bearing performance to the conveyor frame 54.

Arranged in the longitudinal direction, the conveyor frame 54additionally provides a plurality of support rails that extend thelongitudinal length of the service line 10, from the idler end 48 to thedrive end 46. The support rails are arranged as two inner support rails78 a, 78 b and two outer support rails 80 a, 80 b. The inner supportrails 78 a, 78 b are generally positioned symmetrically about thelongitudinal centerline of the service line 10, while the two outersupport rails 80 a, 80 b are situated proximal to the longitudinal wallsof the trench 40. The inner support rails 78 a, 78 b and the outersupport rails 80 a, 80 b may be fixedly attached in place by rivets,threaded fasteners (e.g., bolts), metallurgic bonding (e.g., weldedattachment), or any other suitable means to achieve a secure attachment.

Having reference to FIG. 4, the inner support rails 78 a, 78 bcooperatively define a gap spacing for the central stationary platform38 provided between the endless belts 36 a, 36 b. The inner supportrails 78 a, 78 b each provide a respective seat 82 a, 82 b configured toreceive and support the central stationary platform 38. In theembodiment shown, the central stationary platform 38 is provided in theform of fiberglass or thermoplastic grating. In addition, for eachendless belt 36, the respective opposing inner and outer rails 78 a, 80a define a gap spacing to receive a support deck 84. The support deck 84generally includes a plurality of modular grid panels 86 adapted to bepositioned end to end relative to one another along the longitudinallength of the service line 10. The modular grid panels are provided witha length that aligns the point of contact between adjacent grid panelson a transverse cross-member 68, providing weight-bearing supportthereto. The support deck 84 is positioned between the upper transportportion 42 and lower return portion 44 of the endless belt 36, generallyin close proximity to the upper transport portion 42. In this way, thesupport deck 84 provides support to the upper transport portion 42 ofthe endless belt 36, and thereby a load placed thereon from a wheeledstructure placed upon the conveyor system 20. To facilitate sliding ofthe endless belt over the support deck 84, a belt contact surface in theform of a plurality of wear plates 88 is provided between the uppertransport portion 42 and the support deck 84. The belt contact surfaceis the portion of the support deck 84 facing the endless belt 36 duringnormal use. The belt contact surface can have a thickness so that, as itwears through use with the endless belt 36, it continues to facilitatesliding of the endless belt 36 thereover until the belt contact surfaceis worn out.

The wear plates 88 form a structure that extends along a top of thesupport deck 84 and contacts the upper transport portion 42 of theendless belt 36. The arrangement of the inner and outer support rails 78a, 78 b, 80 a, 80 b may additionally be used to mount the guide member66 supporting the lower return portion 44 of the endless belt 36. Asshown, the inner and outer support rails 78 a, 80 a provide respectiveguide hangers 90, 92 that support the guide member 66 in a transversedirection relative to the longitudinal direction of the service line 10.As shown, the guide member 66 is provided with a plurality of rollers 94that support an outward surface 96 of the endless belt 36 along thelower return portion 44.

Continuing with FIG. 4, also provided between the upper transportportion 42 and the lower return portion 44 of the endless belt 36, andin particular between the support deck 84 and the lower return portion44 is a debris deflector 98. The debris deflector 98 provides a barrierto protect the lower return portion 44 from debris falling from thesupport deck 84, in particular where the support deck 84 is provided inthe form of the modular grid panels. The debris deflector 98 isgenerally mounted on an angle directed downwardly towards thelongitudinal centerline of the service line. The debris deflector 98 maybe mounted on dedicated brackets, or may be mounted on the guide hangers90 and 92 used for supporting the guide members 66 (as shown). Thedebris deflector 98 is generally configured to provide a contiguousbarrier between adjacent cross-members, so as to maximize the protectionfrom falling debris. In some embodiments, the debris deflector 98 may beprovided in the form of multiple panels arranged and fastened inside-by-side relationship to one another.

It will be recognized that the arrangement of the support deck 84, thedebris deflector 98 and the longitudinally-spaced cross-members 68define a partial enclosure in the region between the upper transportportion 42 and the lower return portion 44 of the endless belt 36. Toassist in reducing the likelihood of freezing conditions on the conveyorsystem 10, in particular sections exposed to the outside environment,such as the loading zone 26 shown in FIG. 1, at least a portion of theconveyor system 20 may include a heater in these partial enclosuresbetween adjacent cross-members 68. Referring to FIGS. 3 and 4, theconveyor system 20 provides a heater 100 positioned between the supportdeck 84 and the debris deflector 98, extending in the longitudinaldirection across one or more of the partial enclosures delimitedlongitudinally between adjacent cross members 68. Accordingly, thepartial enclosures containing the heater 100 provide a region of higherheat concentration relative to other areas within the trench 40, inparticular the area below the debris deflector 98. In this way, thesupport deck 84, the endless belt 36 supported thereon, and theplurality of wear plates 88 positioned therebetween receive heat fromthe region of higher heat concentration, thereby reducing the likelihoodof a freeze event in the conveyor system 20. It will be appreciated thatfreeze events in conveyor systems can result in extensive damage to theendless belt 36 and/or drive module 56.

To enable passage of the heater 100 between adjacent partial enclosuresseparated by the cross-members 68, the cross-members 68 are adapted withone or more pass-through apertures 102, depending on whether the heateris adapted to pass once through the desired heated portion, or in aserpentine path therethrough. In the embodiment shown in FIG. 4, twopass-through apertures are provided for each side of the conveyor system20.

It will be appreciated that the heater 100 may take on a variety offorms. For example, the heater 100 may be configured as a convectiveheater, such as a convective tube heater including both smooth andfinned-tube varieties. A convective tube heater will generally be partof a fluid circuit having an electric or gas-fired heater module todeliver a heated fluid therein. The heater 100 may also be configured asa radiant heater such as a gas-fired radiant tube heater, or a resistiveelectrical heating element.

The debris deflector 98 may be formed from any suitable materialincluding but not limited to metal (e.g., stainless steel, galvanizedsteel, aluminum, etc.), thermoplastics (e.g., polypropylene,polyethylene, etc.) and composites. To promote direction of the emittedheat from heater 100 towards the support deck 84, the debris deflector98 may be adapted with at least a selected level of thermalreflectivity. The thermal reflectivity may be achieved by constructingthe debris deflector 98 in the form of a radiant barrier. Alternatively,a radiant barrier may be separately formed and applied to the debrisdeflector 98, for example in the form of a thin radiant barrier sheetattached thereto. Radiant barriers are typically highly reflectivematerials (e.g., aluminum or polished stainless steel foil) applied to asubstrate. Exemplary substrates may include kraft paper, oriented strandboard, plastic films and plywood. For environments that experience highmoisture levels, for example a car wash tunnel, the substrate may be ofmetal or thermoplastic construction. Exemplary thermoplastic substratesmay include polypropylene or polyethylene foam core. In general, thematerial applied to the substrate should exhibit an emittance of lessthan 0.25, as measured by ASTM C1371. In addition to polished metallicfilms, low-emittance coatings such as metal oxide may be used on asuitable substrate. It will be appreciated that the side of the debrisdeflector 98, or separately formed sheet, facing the support deck 84 isthe side adapted to receive the highly reflective material. In otherwords, the highly reflective material, and thus the effective side ofthe radiant barrier is intended to face the region of higher heatconcentration between the debris deflector 98 and the support deck 84.

Having regard to FIGS. 5 and 6, shown is a debris deflector 198according an alternative embodiment. As the debris deflector 198 isarranged in the conveyor system 20 in substantially the same way asdebris deflector 98, only the differences associated with thisalternative embodiment are discussed. The debris deflector 198 includesa debris portion 110 that is positioned under the support deck 84, and awater collection portion 112 that extends outwardly therefrom, towards arespective side wall of the trench 40. The water collection portion 112is intended to facilitate cleaning of the debris portion 110 of thedebris deflector 198, without the need for substantial disassembly andassociated downtime of the conveyor system. With this arrangement, asprayer or suitable wash nozzle 114 may be positioned as shown todeliver a stream of water directly upon the water collection portion 112of the debris deflector 198, promoting a wash effect to removeaccumulated debris from the debris portion 110. Access to the watercollection portion 112 may be achieved by removing side panels 116, orwhere the side panels 116 are provided in the form of fiberglass orthermoplastic grating, wash water may be delivered directlytherethrough. The use of grates for the side panels 116 will also permita greater volume of wash and rinse water from the wash tunnel to becaptured by the water collection portion 112, enhancing the cleaningeffect of the debris deflector 198 during normal wash tunnel usage.

As shown, the water collection portion 112 of the debris deflector 198is generally arranged at an angle relative to the debris portion 110,with its terminal lateral edge 120 being positioned proximal theunderside 122 of the side panel 116. The debris deflector 198 isprovided with a curved transition 124 between the water collectionportion 112 and the debris portion 110 to deflect the impingement ofrinse water, with reduced turbulence, therein resulting in an effectiveflushing of debris from the debris portion 110 of the debris deflector198.

The debris deflector 98, 198 may be formed of stamped or formedstainless steel, or galvanized steel to provide a rust-inhibitingeffect. In an alternative embodiment, the debris deflectors 98, 198 maybe formed of a thermoplastic material, for example a polyolefin, a lowor high-density polyethylene, polyvinyl chloride, or an acrylonitrilebutadiene styrene (ABS), and may include suitable fillers or additivesto achieve the desired performance characteristics. In general, suitablematerials will exhibit resistance to wear, corrosion and pitting, aswell as low moisture absorption and low reactivity to chemicals.Suitable materials should also exhibit a general non-stick behavior(i.e., as achieved through improved surface smoothness and a lowcoefficient of friction) in relation to oil and grease, as well as dirtand salt. In one embodiment, the debris deflector 98, 198 may be formedof polypropylene or polyethylene, and may include glass fibers toimprove impact performance at low temperature.

When formed of thermoplastic material, the debris deflector 98, 198 maybe formed via any suitable molding process, including but not limited tovacuum forming, compression molding and thermoforming. When molded, athermoplastic debris deflector may incorporate one or more structuralribs 126 (as seen in FIG. 6). The structural ribs 126 provide additionalrigidity to the debris deflector 98, 198, and establish sluice-likechannel-ways 128 that direct water flow, enhancing the wash effect.

As stated earlier, and having regard to FIG. 2a , the upper transportportion 42 of the endless belt 36 moves in tension from the idler end 48towards the drive end 46 by drive member 56, while the lower returnportion 44 moves in a slackened state from the drive end 46 towards theidler end 48. In the slackened state, the lower return portion 44 of theendless belt 36 may be subject to greater lateral movement, having thepotential to create belt tracking and alignment issues. This isparticularly evident at the idler end 48 where the axially elongatedroller 52 is not provided with engagement teeth as found on the opposingdrive member 58 at the drive end 46. Misalignment and poor tracking ofthe endless belt 36 can cause excessive wear on the conveyor mechanism,necessitating increased maintenance and associated downtime. Issues ofmisalignment of the endless belt 36 can increase upon aging of theendless belt 36, generally due to belt stretch. Accordingly, in analternative embodiment, a least one pair of lateral guide rollers areincorporated into the conveyor system 20.

Having regard to FIG. 7, shown is the idler end 48 of the conveyorsystem 20, with the endless belt and associated support componentsremoved for clarity. Associated with each endless belt is a pair oflateral guides 130 a, 130 b, mounted to the conveyor frame 54. The pairof lateral guides 130 a, 130 b are arranged to engage the lower returnportion 44 of the endless belt 36, as best seen in FIG. 2c with respectto lateral guide 130 b. Having regard to FIGS. 7 and 8, each lateralguide 130 a, 130 b is provided with at least one roller (first roller132) presenting a first roller surface 134 positioned to engage arespective lateral edge of the lower return portion 44 of the endlessbelt 36. In the embodiment shown, each lateral guide 130 a, 130 b ispresented as having two stacked rollers, that is the first roller 132and a second roller 136. The addition of the second roller 136 providesa second roller surface 138 positioned to engage the endless belt 36 ina more slackened state. In an alternative embodiment, the height of thefirst roller 132 can be large enough to span the expected range of thepath of the endless belt 36, thereby mitigating the need for two or morerollers. In general, a newly installed endless belt 36 having verylittle operational time will exhibit less slack, and therein align tothe first roller surface 134 of the first roller 132, as shown in FIG.2c . With usage and ageing of the endless belt, additional slack arisingfrom stretch in the endless belt 36 may cause the endless belt 36 todisplace downwardly, with the lateral edges of the lower return portion44 aligning with the second roller surface 138 of the second roller 136.Further, changes in ambient temperature can cause the lengthening andshortening of the endless belt 36, causing it to align with the firstroller surface 134 or the second roller surface 138. Accordingly, thelateral guides 130 a, 130 b are configured to provide lateral supportover the useable lifespan of the endless roller 36.

The lateral guides 130 a, 130 b generally include the at least oneroller (first and second rollers 132, 136 as presented herein) mountedupon a bracket 140, as best seen in FIG. 8. The bracket 140 provides amount portion 142 that is fastened to the conveyor frame 54, and aroller support portion 144 that receives the at least one roller(rollers 132, 136 in the embodiment shown). The rollers may be anysuitable material, including but not limited to polymeric or rubbermaterials (i.e., rubber-tired caster wheels), and may include a suitablebearing member, such as a bushing or a bearing, to facilitate rotationabout an axis A. In one embodiment, the bearing may be a sealed bearingto prevent the ingress and fouling of the bearing due to contaminatedwater and debris. To facilitate lateral adjustability of the lateralguides 130 a, 130 b, the mount portion 142 of the bracket 140 may beprovided with a slotted aperture 146 at each point receiving a fastener(i.e., bolt 148). Accordingly, the lateral guides 130 a, 130 b can belaterally adjusted as necessary to ensure proper tracking of the endlessbelt 36. In general, the lateral guides are positioned to ensurecontinued traction with the edge of the endless belt 36, so as tominimize wear due to sliding friction, in particular with systems havingheavier particulate buildup.

Having regard to FIG. 3a , each cross-member 68 may be adapted to mountdirectly upon the opposing surfaces 70 and 72, for example by weldedattachment to an anchorage bar 150 embedded in the concrete at the upperlongitudinal edge the trench 40. While effective, direct attachment canbe labor intensive as supporting the heavy cross member 68 duringattachment can be difficult. Accordingly, in an alternative embodiment,the plurality of cross members 68 are attached on opposing ends to arespective cross-member mount bracket 152, as shown in FIG. 9. Thecross-member mount bracket 152 includes an anchorage portion 154configured for attachment to the anchorage bar 150, and a cross-memberportion 156 configured to receive and support the cross-member 68. Asshown, each side of the trench 40 includes along the upper longitudinaledge 158 the anchorage bar 150, generally provided in the form of angleiron embedded in the concrete. At each location along the trench 40where a respective cross-member 68 is positioned, a mount bracket 152 iswelded to the anchorage bar 150. The mount bracket 152 is easier tolocate in relation to a desired vertical elevation on the anchorage bar150, and may be tack-welded in place prior to permanent attachment toenable alignment and level verification over the longitudinal length ofthe trench prior to final welding. With all mount brackets 152 welded inposition to support the desired arrangement of cross-members 68, thecross-members are attached at opposing ends to respective cooperatingmount brackets. Attachment may be achieved using suitable fasteners, forexample bolts 160. To permit for lateral adjustment, in particular wherethe trench 40 may exhibit variation in width along its longitudinallength, the cross-member mount portion 156 of at least one of thecooperating mount brackets 152 is provided with slotted apertures 162 toreceive the fastener (bolts 160). In this way, slight variations inwidth of the trench 40 are accommodated by the mount brackets 152,reducing the need for custom-sized components. This slotted arrangementalso allows adjustment of the conveyor system 20 for straightness in theevent that the trench 40 is not straight.

As stated previously, the wear plates 88 facilitate sliding of theendless belt 36 over the support deck 84, and is located between theupper transport portion 42 and the support deck 84, as best seen in FIG.4. Having regard to FIGS. 10 and 11, shown is a portion of the conveyorsystem 20 with the endless belt removed to highlight features of thewear plates 88. The wear plates 88 are supported upon the plurality ofmodular grid panels 86 of the support deck 84, and are adapted to sitend-to-end relative to one another. Each of the wear plates 88 includesa leading edge 166 and a trailing edge 168, wherein the leading andtrailing edges 166 and 168 are provided with complementary profiles tofacilitate fit and alignment between adjacently positioned wear plates88. In the embodiment shown, the complementary profile is provided inthe form of a chevron aligned to the direction of travel of the vehiclethrough the wash tunnel. At least one of the leading and trailing edges166 and 168 of the wear plates 88 may be chamfered to reduce thelikelihood of wear upon the endless belt.

The wear plates 88 are made from a material that is at least partiallythermoplastic, and, in particular, at least partially polyethylene, suchas an ultra-high-molecular-weight polyethylene (“UHMWPE”), which is alsoknown as high-modulus polyethylene (“HMPE”). UHMWPE is a thermoplasticpolyethylene that has extremely long chains. The longer chains serve totransfer load more effectively to the polymer framework by reinforcingintermolecular interactions. Further, UHMWPE has low moistureabsorption, a very low coefficient of friction, a high strength, and ishighly resistant to abrasion as a result of the longer chains,especially in comparison to carbon steel. Further, UHMWPE is veryresistant to corrosion. Some particular exemplary materials that can beused to manufacture the wear plates are virgin UHMWPE such as availablefrom Röchling Engineering Plastics and the Garland ManufacturingCompany, reprocessed UHMWPE such as available from Röchling EngineeringPlastics, glass filled UHMWPE such as available from Quadrant PlasticComposites Inc., ceramic filled UHMWPE such as available from PolymerIndustries Inc. and Quadrant Plastic Composites Inc., and cross-linkedUHMWPE such as available from Röchling Engineering Plastics and PolymerIndustries Inc.

Alternatively, in other embodiments, the wear plates can be made from amaterial that is at least partially high-density polyethylene (“HDPE”).HDPE is also suitable for use for construction of the wear plates 88. Inanother embodiment, a proprietary polyethylene, Polystone™ sold byRöchling Engineering Plastics, can be used to manufacture the wearplates.

The material of the wear plates 88 can be selected it has a hardnessH_(WP) that is lesser than the hardness H_(BS) of the plastic beltsegments in some scenarios.

The costs for the manufacturing of wear plates form these materialsranges from 63% to over 200% of the price using stainless steel in somecases, based on the current prices of stainless steel and thesethermoplastics. Depending on the material selected and application,suitable thickness ranges are in the 3/16 inch to ⅜ inch range (5-10 mm)in some scenarios.

Traditionally, the use of such materials for belt contact surfaces wasdeemed unsuitable as dirt trapped between the endless belts and the beltcontact surfaces caused the belt contact surfaces to wear at anunsatisfactory rate without significant improvements to the wear of theendless belts. Wearing of the endless belts and the belt contact surfaceoccurs in the form of erosion. As the endless belts are worn down, thepins holding belt segments together are exposed and can be deformed andpop out, allowing the belt segments to separate. Erosion of the beltcontact surface can accelerate endless belt wear where the endless beltis in contact with the underlying structures.

It has been found that, by using a belt rinsing system that introducesand drains a rinsing fluid between the endless belts and the beltcontact surfaces, the dirt trapped between the endless belts and thebelt contact surfaces can be reduced and that the wear rate of both theendless belts and the belt contact surfaces can be reduced.

That is, by making the belt contact surface (i.e., the wear plates 88)from a softer material than stainless steel that is traditionally used,and by rinsing away debris from the interface between the endless belts36 a, 36 b and the support deck, the lifetime of the endless belts 36 a,36 b can be increased as a result of the lower wear from contact withthe wear plates 88.

Certain thermoplastics, such as UHMWPE and HDPE have been found to besuitable due to their possession of certain characteristics. Thesematerials provide a sufficiently low coefficient of friction, and aresufficiently resistant to abrasion. The wear plates 88 are inexpensiveto replace relative to the replacement cost of the endless belts 36 a,36 b. The replacement cost of an endless belt 36 a, 36 b can be high asthere is a significant amount of manual labor in disassembling the beltsegments to be replaced. Wear plates made from a material that issubstantially UHMW have been found to have a service lifetime thatranges from 11% to 200% of the durability of wear plates made fromstainless steel. Of more interest is that, due to the relative softness,higher resistance to abrasion, and lower coefficient of friction of thematerial compared to stainless steel traditionally employed in theseapplications, the wear rate of the endless belts is reduced, thusextending their service lifetime significantly, anywhere from 50% to1700% in some cases.

Another characteristic of thermoplastics is that they generally have ahardness H_(WP) that is lesser than the hardness H_(BS) of the beltsegments of the endless belts 36 a, 36 b. As a result, the wear plates88 are designed to improve the lifetime of the endless belt 36 bysacrificing the lifetime of the wear plates 88.

Polyethylenes and other thermoplastics are subject to thermal expansionand contraction. In the car wash environment, the range of temperaturesthat the wear plates 88 are subject to is significant. The wear plates88 have a longitudinal length of approximately 44 inches and have beenfound to expand and contract +/−0.2 inches over a typical operationalambient temperature range. In order to compensate for these expansionsand contractions, expansion gaps between the leading and trailing edges166 and 168 of the wear plates 88 of 0.2 inches or greater are provided.

Each wear plate 88 is provided with a plurality of debris slots 170 thatpermit the evacuation of debris therethrough, so as to reduce theaccumulation of debris between the endless belt and the wear plates 88.Each debris slot 170 includes a first slot end 172 and a second slot end174, and is provided with a width of 10 mm, although widths of between 8to 25 mm may be implemented. Each debris slot 170 may be linear (i.e.,straight) and may be arranged at an angle θ relative a longitudinalcenterline L of the wear plate 88. As shown, the debris slot 170 isoutwardly angled from the longitudinal centerline L in the direction ofthe first slot end 172 towards the second slot end 174. The angle θ ofeach debris slot 170 is 35° relative to the longitudinal centerline L ofthe wear plate 88, although angles between 25° to 45° may beimplemented. In general, angle selection is based on observed belt wear.It has been determined that angles within this range, and in particularat 35° relative to the longitudinal centerline L of the wear plate 88result in the least amount of endless belt wear during use, thereinincreasing the usable lifespan of the endless belt and wear plates.

The first slot end 172 and the second slot end 174 of each debris slot170 can be provided with an inwardly sloped bevel 176, as shown in FIG.12a . It has been determined that maximum wear of the endless beltoccurs where the endless belt passes over a sharp edge perpendicular tothe direction of belt travel. Accordingly, with the first and secondslot ends 172 and 174 having the inwardly sloped bevel 176, inparticular at the second slot end 174, the extent of belt wear isreduced, particularly when the wear plates are constructed of stainlesssteel. Between the first and second slot ends 172 and 174 of the debrisslot 170, the opposing edges 178 a and 178 b remain unbeveled, that isthey remain as sharp edges, as shown in FIG. 12b . As the endless beltis passing over these sections of the debris slot 170 at an angle (i.e.,35° relative to the longitudinal centerline L of the wear plate 88), theextent of belt wear is minimal. Moreover, by maintaining these edgessharp as shown, they provide a stripping action to remove debris fromthe underside of the endless belt, without excessive wear thereto.

It will be appreciated that while both the first and second slot ends172 and 174 are shown as being beveled, in some embodiments, only one ofthe first and second slot ends 172 and 174 is beveled. In an alternativeembodiment, only the second slot end 174 is beveled.

By using certain thermoplastics that are softer than stainless steel,have a low coefficient of friction, and/or a high resistance to abrasionin constructing the wear plates, it has been found that the beveling ofthe debris slots 170 as shown in FIGS. 12a and 12b can be omittedwithout materially increasing wear on the endless belt 36. The bevelingof the debris slots 170 adds to the manufacturing costs of the wearplates 88 and, thus, the ability to omit this feature without materiallyimpacting the lifetime of the endless belt 36 is another benefit to theuse of thermoplastics in the construction of the wear plates 88.

In the embodiment shown in FIG. 11, each wear plate 88 provides 8 debrisslots 170, generally presented in two rows of 4 arranged across the wearplate 88. Within each row, the 4 debris slots are arranged in two pairedsets of debris slots, with the two paired sets of debris slots beinglongitudinally offset relative to one another. The arrangement of thedebris slots 170 is such that the leading and trailing ends 172 and 174of successive debris slots 170 align, so as to reduce the number oflocations having increased potential for belt wear. As shown, alignmentbetween successive debris slots occurs along longitudinal centerline L,as well as alignment line AL_(A) and alignment line AL_(B).

It will be appreciated that while each wear plate 88 is shown as having8 debris slots 170, in other embodiments, the number of debris slots 170may be fewer or greater, depending on the extend of debris removalrequired. While the leading and trailing ends 172 and 174 of all debrisslots 170 may be machined with the aforementioned inwardly sloped bevel,in some embodiments, only the debris slots 170 arranged proximal thelongitudinal centerline L of the wear plate 88 may be beveled. In otherpreferred embodiments, the debris slots 170 are not beveled.

As shown in FIG. 4, the inner and outer support rails 78 a, 80 a providerespective guide hangers 90, 92 that support the guide member 66 in atransverse direction relative to the longitudinal direction of theservice line 10. Having regard to FIG. 13, shown is the guide member 66in isolation to highlight specific features thereof. Guide member 66includes a plurality of rollers 94 (94 a, 94 b, 94 c) mounted on astationary shaft 180 supported at a first end 182 by guide hanger 90(not shown for clarity), and at a second end 184 by guide hanger 92. Insome embodiments the stationary shaft 180 is a stainless steel shaft,with at least one of the first and second ends 182 and 184 beingconfigured with a suitable keyed interface with respective guide hangers90 and 92 to prevent rotation of the stationary shaft 180 relativethereto. Each roller 94 (94 a, 94 b, 94 c) provided is rotatably mountedon the stationary shaft 180 using a suitable bushing or bearinginterface therebetween. In the embodiment shown, a low frictionthermoplastic bushing 186 is used. Suitable thermoplastics include, butare not limited to acetal (i.e., Delrin™) and UHMWPE. As shown in FIG.14, the thermoplastic bushing 186 is configured with a central bearingmember portion 188 that engages a shaft aperture 190 of roller 94, aswell as a first bushing extension 192 and a second bushing extension194. The central bearing member portion 188 of the thermoplastic bushing186 is press-fit or otherwise mounted in the shaft aperture 190, so asto rotate with the roller 94. Accordingly, upon rotation of the roller94 during use, the thermoplastic bushing 186 rotates upon the stationaryshaft 180, with the thermoplastic bushing 186 providing a low frictioninterface therebetween.

The guide member 66 additionally includes a series of protective sleevesthat cover the stationary shaft 180 and serve to protect the interfacebetween the stationary shaft 180 and the thermoplastic bushings 186 fromdebris and contaminated water. As shown, a first and second outer sleeve196 and 198 is provided between respective guide hangers 90 and 92 andthe outer rollers 94 a and 94 b. A first and a second inner sleeve 200and 202 are provided between the respective outer rollers 94 a and 94 band the middle roller 94 c. It will be appreciated that the inner andouter sleeves also serve as spacers to maintain the rollers 94 in thedesired position on the stationary shaft 180.

The first and second outer sleeves 196 and 198 are configured to remainstationary during use. Accordingly, at each end 182 and 184 of thestationary shaft 180, a fixed non-rotatable interface is establishedbetween the stationary shaft 180 and the first and second outer sleeves196 and 198 associated therewith. Having regard to FIG. 15 detailing thearrangement at the first end 182, a fixed bushing 204 is providedbetween the first outer sleeve 196 and the stationary shaft 180. Theinterface between the stationary shaft 180 and the fixed bushing 204, inparticular the outside diameter of the stationary shaft 180 relative tothe inside diameter of the fixed bushing 204 is sized to establish aninterference fit therebetween. As such, a fixed non-rotatablerelationship is established between the stationary shaft 180 and thefixed bushing 204. Similarly, the interface between the fixed bushing204 and the first outer sleeve 196, in particular the outside diameterof the fixed bushing 204 relative to the inside diameter of the firstouter sleeve 196 is sized to establish an interference therebetween. Assuch, a fixed non-rotatable relationship is established between thefixed bushing 204 and the first outer sleeve 196. Accordingly, the firstouter sleeve 196, as well as the second out sleeve 198 which is mountedin an identical manner relative to the second end 184 remain fixed inrelation to the stationary shaft 180.

On the opposing end of the first outer sleeve 196, that is where itengages the first bushing extension 192 of the thermoplastic bushing 186at the roller 94 a, the inside diameter of the first outer sleeve 196relative to the outside diameter of the first bushing extension 192 issized to establish a slip-fit therebetween. As such, first outer sleeve196 remains fixed while the thermoplastic bushing 186 is permitted torotate relative thereto. It will be appreciated that the opposing end ofthe second outer sleeve 198 is similarly configured relative to thethermoplastic bushing 186 at the roller 94 b, so as to achieve the sameslip-it relationship therebetween.

Unlike the first and second outer sleeves 196, 198, the first and secondinner sleeves 200 and 202 are configured to rotate with the rollers 94.Accordingly, having regard to the first inner sleeve 200, the interfacebetween the first inner sleeve 200 and the second bushing extension 194at roller 94 a, in particular the inside diameter of the first innersleeve 200 relative to the outside diameter of the second bushingextension 194 is sized to establish an interference fit therebetween.Each end of the first inner sleeve 200 is configured in this way,therein causing the first inner sleeve 200 to rotate upon rotation ofthe rollers 94 a and 94 c. It will be appreciated that the second innersleeve is similarly configured, relative to the rollers 94 c and 94 b.

To reduce the likelihood of contamination of the thermoplastic bushing186, in particular at the interface between the thermoplastic bushing186 and the stationary shaft 180, additional seal rings 206 (i.e.,rubber O-rings) may be implemented. As shown, a seal ring 206 isprovided at the interface between each bushing extension 192 and 194 ofthe thermoplastic bushing 186, and the respective inner sleeve 200 and202 or outer sleeve 196, 198 to which it engages. Seal ring is seated ina suitable channel at the interface, for example as provided by sealring channel 210 in each of the first and second bushing extensions 192and 194.

Suitable materials for the rollers 94 include, but are not limited torubber tired wheels (i.e., caster wheels). The use of rubber tiredwheels has the benefit of supporting the endless belt without causingdamage to the belt surfaces by maintaining traction sufficient toprovide continuous rotation of the wheels with belt movement.

It will be appreciated that while the stationary shaft 180 is shown asbeing solid, in an alternative embodiment, the stationary shaft 180 maybe a hollow tube.

In an alternative embodiment, each guide hanger 90 and 92 mayadditionally include a side roller 208, for example as shown in FIG. 16.The side roller 208 may be a rubber tired wheel similar to the rollers94 of the guide members 66, and are configured to engage the edge of theendless belt 36, maintaining the endless belt 36 laterally centeredrelative to the opposing guide hangers 90 and 92.

Reference is made to FIGS. 17a -20, which shows the conveyor system 20with an optional rinsing system 300. The rinsing system 300 includes arinsing system conduit arrangement 302 (a portion of which is shown inFIGS. 17a and 17b ), which is connectable to a source of rinsing systemliquid (e.g., a city water supply). The rinsing system 300 furtherincludes at least one belt rinsing arrangement 304. In the presentexample, the rinsing system 300 includes a plurality of belt rinsingarrangements 304 spaced longitudinally apart for rinsing the uppertransport portion 42 of the endless belt 36.

Each belt rinsing arrangement 304 includes a rinsing system dirtpass-through aperture 306 in the support deck 84, over which the uppertransport portion 42 of the endless belt 36 travels during operation. Ascan be seen, in the embodiment shown in FIG. 17a , the rinsing systemdirt pass-through aperture 306 is provided in a rinsing system wearplate 308. The rinsing system dirt pass-through aperture 306 may besimilar to the debris slots 170 in the wear plates 88, but may be widerin the direction of travel (shown at Dt) of the endless belt 36 forreasons provided below.

Each belt rinsing arrangement 304 further includes at least one rinsingsystem outlet 310 from the rinsing system conduit arrangement 302positioned proximate to the rinsing system dirt pass-through aperture306 a and positioned to eject rinsing system liquid (shown at 312 inFIGS. 18 and 19) onto the endless belt 36 upstream from a downstreamedge 314 of the rinsing system dirt pass-through aperture 306 a in orderto capture at least some of the ejected liquid 312 through the rinsingsystem dirt pass-through aperture 306 a. The terms ‘upstream’ and‘downstream’ are both in relation to the direction of travel Dt of theupper transport portion 42 of the endless belt 36. The upstream edge ofthe rinsing system dirt pass-through aperture 306 a is shown at 315.Additional rinsing system dirt pass-through apertures 306 b enables theflushing of ejected liquid 312 downstream of the rinsing system dirtpass-through apertures 306 a.

Put another way, the rinsing system 70 can rinse off dirt from theendless belt 36 so as to prevent that dirt from causing wear on the belt36 as the belt 36 moves along during operation. The dirt may be presentdirectly at the sliding interface between the belt 36 and the wearplates 88 and 308. Additionally, the dirt may be present at the pins(shown at 316) that pivotally connect belt segments (shown at 318) thatmake up the belt 36.

Pockets (shown at 320) are present in the endless belt 36 and someportions of the pins 316 are exposed in the pockets 320. It is thereforebeneficial for the rinsing system 300 to be able to eject rinsing systemliquid into the pockets 320 to rinse dirt from the pins 316. Thisinhibits dirt from migrating into the interface between the pins 316 andthe associated surfaces of the belt segments 318, which reduces the wearthat can occur on the belt segments 318 at that interface. Such wearcontributes to ovalizing of the apertures in the belt segments 318 inwhich the pins 316 reside, causing the belt 36 to lengthen andcontributing to accelerated wear and failure of the belt 36.

Thus it may be said that the endless belt includes a plurality of beltsegments 318 that are pivotally connected to one another via at leastone pin 316 that extends laterally. The endless belt 36 includes atleast one pocket 320 that exposes the at least one pin 316. The at leastone rinsing system outlet 310 is positioned to eject rinsing systemliquid into the at least one pocket 320 onto the at least one pin 316 toremove dirt from the at least one pin 316.

The rinsing system outlet 310 may be any suitable type of outlet that iscapable of ejecting rinsing system liquid the distance needed to removedirt from the endless belt 36. In some examples, the pressure of therinsing system liquid at the rinsing system outlet 310 may be about 20psi or higher. In some examples, it may be 40 psi or higher. The rinsingsystem outlet 310 may, for example, be a nozzle.

Reference is made to FIG. 20. As can be seen, the rinsing system outlets310 are positioned below the wear plates 308 and are positioned to ejectthe rinsing system liquid up through the rinsing system dirtpass-through aperture 306 into the belt 36. The rinsing system dirtpass-through aperture 306 has an elongate cross-sectional shape and issized to permit the ejecta 312 (i.e., the rinsing system liquid ejectedtherefrom) to leave upwardly from the rinsing system dirt pass-throughaperture 306, to hit the endless belt 36 and to fall through the rinsingsystem dirt pass-through aperture 306 after hitting the endless belt,bringing dirt with it, as shown in FIG. 20. For example, in theembodiment shown, the outlet 310 is well below the wear plate 308 and sothe ejecta 312 pass upwardly through the rinsing system dirtpass-through aperture 306, hit the belt 36 and then fall back downthrough the aperture 306.

The apertures 306 are shown as being angled, similarly to the apertures(slots) 170 in the wear plates 88, for the purpose of ensuring thatsegments of the belt 36 are always supported and do not impact againstan aperture edge. This is the same reason described for the angle of theslots 170. Similar angular ranges may be used for the orientation (i.e.,the angle) of the apertures 306.

As can be seen, each rinsing system outlet 310 is in the form of a fanjet nozzle configured for ejecting rinsing system liquid 312 in the formof ejecta 312 having an elongate cross-sectional shape (e.g., a flatspray pattern).

Referring to FIG. 19, dashed lines shown at 330 a and 330 b representthe side edges of the endless belt 36. The belt 36 has a width W. As canbe seen, the at least one belt rinsing arrangement 302 includes enoughof the rinsing system outlets 306 to eject rinsing system liquid 312(i.e., ejecta 312) on the entire width of the belt 36. There is someoffset between the apparent position of the ejecta 312 and the positionof the side edges 330 a and 330 b of the belt 36 in the view shown inFIG. 19 however, it will be understood that this is merely a result ofthe difference in elevation of the outlets 310 and the belt 36.

In FIG. 19, a debris deflector 332 is provided and may be similar to anyof the debris deflectors shown and described herein. The debrisdeflector 332 is positioned underneath the rinsing system dirtpass-through aperture 306 to collect dirt falling through the rinsingsystem dirt pass-through aperture 306, and sloped downwardly away fromthe rinsing system dirt pass-through aperture 306 in order to transportcollected dirt towards a dirt collection area shown at 334.

Reference is made to FIGS. 21 and 22, which show another rinsing system340, which includes a rinsing system conduit arrangement 342 which isconnectable to a source of rinsing system liquid (e.g., a city watersupply or a reclaim water system). The rinsing system 340 furtherincludes at least one sprocket rinsing arrangement 344 configured torinse and remove dirt from a sprocket arrangement 352 that is used todrive the belt 36. The sprocket arrangement 352 in the present exampleincludes a plurality of sprockets 354 that are mounted on a drive shaft356. Alternatively, the sprocket arrangement 352 could include a singlesprocket 354.

The drive shaft 356 in the present example is square and passes throughsquare apertures in the sprockets 354, however it will be understoodthat other shapes for the drive shaft 356 and apertures are possible.The sprocket arrangement 352 has sprocket teeth 358 that engage the belt36 to drive the belt 36. The direction of rotation of the sprocketarrangement 352 is shown at Ds in FIG. 21.

Each belt rinsing arrangement 344 further includes at least one rinsingsystem outlet 360 from the rinsing system conduit arrangement 342. Theat least one rinsing system outlet 360 is positioned proximate to thesprocket arrangement 352 and is positioned to eject rinsing systemliquid 312 onto the sprocket arrangement 352.

As rinsing system liquid 312 is ejected onto the sprocket arrangement352, it rinses some dirt off a portion of the surface of the sprocketarrangement 352 prior to engagement between that portion of the surfaceof the sprocket arrangement 352 and the belt 36. As a result, there isless dirt that would cause wear of the belt 36 during engagement withthe sprocket arrangement 352. Such wear on the belt 36 can reduce theefficacy of the engagement with the teeth 358 on the sprocketarrangement 352. Additionally, the presence of the dirt itself caninhibit good engagement between the teeth 358 and the belt 36 which canresult in increases stresses on certain areas of the belt 36 during suchengagement.

A debris collection guide 362 is provided underneath the at least onerinsing system outlet 360 to collect at least some of the liquid thathas hit the sprocket arrangement 352 and reflected or dripped off thesprocket arrangement 352 thereafter along with any dislodged dirt or anydirt entrained in the reflected liquid or the liquid that has drippedoff the sprocket arrangement 352. The debris collection guide 362 guidescollected debris to a debris collection area (not shown).

Some rinsing system liquid 312 may wind up on the lower return portion44 of the belt 36 instead of in the debris collection guide 362. This isnot considered problematic, since the inner surface of the lower returnportion (shown in FIG. 21 at 364) does not engage any surfaces withsignificant force until reaching the idler drum at the other end of theconveyor system 20. Some of the dirt and liquid collected on the innersurface 364 of the lower return portion 44 of the belt 36 will havefallen off the belt 36 by the time it reaches the other end. As notedabove, the rinsing system 300 can be provided at the upstream end of theupper transport portion 42 of the conveyor system 10, so as to rinse offdirt thereon prior to a lot of sliding engagement with the wear plates88.

FIG. 22 is a perspective view of the rinsing system 340, but with thesprocket arrangement 352 removed. As shown in FIG. 22, the rinsingsystem outlets 360 may be in the form of fan (flat spray) jet nozzles,and may be configured to eject rinsing system liquid 312 in flowpatterns that overlap with one another and which are configured to coverthe width of the sprocket arrangement 352.

As can be seen in FIGS. 21 and 22, optionally, the rinsing system 340further includes at least one belt rinsing arrangement including atleast one rinsing system outlet 360 positioned to spray rinsing systemliquid 312 on the outer face (shown at 366) of the belt 36, to furtherclean the belt 36 while the belt 36 is engaged with the sprocketarrangement 352.

Reference is made to FIGS. 23 and 24, which show a flooder system 400for the conveyor system 20. The flooder system 400 is used to introduceliquid between the endless belt 36 and the wear plate (e.g., wear plate88 or wear plate 308). The flooder system 400 includes a flooder systemconduit arrangement 402 connectable to a source of flooder system liquid(such as city water, or a source of city water mixed with soap, wax orsome other lubricant), and at least one belt flooding member 404. Eachbelt flooding member 404 includes at least one flooding system outlet406 (and optionally a plurality of outlets 406 which are spaced apartlaterally) from the flooding system conduit arrangement 402. The outletor outlets 406 are positioned underneath the endless belt 36 and arepositioned to introduce flooding system liquid 408 between the endlessbelt 36 and the wear plate. The liquid 408 introduced helps to reducefriction between the belt 36 and the wear plate 88 or 308 in part byentraining dirt that may be present therebetween.

The liquid pressure at the outlets 406 may be relatively low, lower thanthe pressure at the outlets 310. For example, the pressure may be about2 psi, but is preferably higher, such as in the range of 5-10 psi oreven higher.

The support deck (e.g., the wear plates 88 and 308) includes a pluralityof dirt pass-through apertures as described above. These apertures willpermit the dirt and liquid from the flooding system to fall through,thereby removing dirt from the interface between the belt 36 and thewear plates 88 and 308. The flooding system 400 may include a pluralityof belt flooding members 404 positioned at selected distanceslongitudinally from one another, such as, for example, about every 20 to30 feet from one another. Optionally, each belt flooding member 404 ispositioned between gratings 412 that support the wear plate 88 or 308and thus may act as a spacer between these gratings 412. The gratings412 need not be gratings and may also be identified more broadly as wearplate support members 412. The wear plate 88 or 308 has flooding systemapertures 414. Each flooding member 404 may include a bar 416 that actsas a manifold and that has a plurality of outlets 406 thereon. Theflooding member 404 may further include seal members 418 (e.g., rubberbushings) that are positioned between the outlets 406 and the underside(shown at 420) of the wear plate 88 or 308 to form a seal therebetween.

FIGS. 26a to 26c show wear plates 500 in accordance with anotherembodiment. The wear plates 500 are similar in size and construction towear plates 88 shown in FIGS. 10, 11, 17 a, and 17 b. In particular,each of the wear plates 500 includes a leading edge 504 and a trailingedge 508, wherein the leading and trailing edges 504 and 508 areprovided with complementary profiles to facilitate fit and alignmentbetween adjacently positioned wear plates 500. In the embodiment shown,the complementary profile is provided generally in the form of a chevronaligned to the direction of travel of the vehicle through the washtunnel. At least one of the leading and trailing edges 504 and 508 ofthe wear plates 500 may be chamfered to reduce the likelihood of wearupon the endless belt.

Like the wear plates 88, the wear plates 500 expand and contract withtemperature changes. To allow for this expansion and contraction, thewear plates 500 are secured via fasteners inserted through fastenerholes 522 that fit within slotted holes of the modular grid panels ofthe support deck. This arrangement allows a degree of freedom ofmovement (or, more to the point, expansion) of the wear plates 500. Itcan also be desirable to maintain the leading and trailing edges 504 and508 in lateral alignment to avoid changes in the lateral profile of thebelt contact surface (i.e., the wear plates 500) in the longitudinaldirection that can serve to more quickly wear and/or damage the endlessbelt.

To this end, the wear plates 500 have mating features inhibiting lateralshifting of the wear plates 500 relative to one another in the form offingers 512 that extend longitudinally (i.e., generally along thedirection of travel of the endless belt) forward from lateral ends ofthe leading edges 504, and corresponding finger recesses 516 that extendlongitudinally from lateral ends of the trailing edges 508. The fingers512 mate with the finger recesses of adjacent wear plates 500 tomaintain the wear plates 500 in lateral alignment while the wear plates500 expand to reduce an expansion gap 518 between the wear plates 500,and contract.

In other embodiments, the fingers can extend longitudinally from thetrailing edge and mate with corresponding finger recesses of the leadingedge of an adjacent wear plate. Alternatively, a finger and a recess canbe located on opposite lateral ends of each leading and trailing edgeand mate with the corresponding features of adjacent wear plates. Othertypes of mating features that inhibit lateral shifting of the wearplates will occur to those skilled in the art.

The wear plates 500 also have debris slots 520 that permit theevacuation of debris therethrough, so as to reduce the accumulation ofdebris between the endless belt and the wear plates 500.

FIGS. 27a and 27b show two variants of the design of the wear plates. Awear plate 600 shown in FIG. 27a has fingers 604 that extendlongitudinally (i.e., generally along the direction of travel of theendless belt) forward from lateral ends of the leading edge 606, andcorresponding finger recesses 608 that extend longitudinally fromlateral ends of the trailing edge 610. The fingers 604 mate with thefinger recesses of adjacent wear plates 600 to maintain the wear plates600 in lateral alignment while the wear plates 600 expand to reduce anexpansion gap between the wear plates 600, and contract. A set of fourlocating slots 612 are positioned two along each lateral side of thewear plate 600. The wear plate 600 has a pattern of debris slots 616that differs from those shown in the previous figures. In particular,the debris slots 616 are wider and shorter, enabling ample drainagewithout significantly affecting the structural integrity of the wearplate 600. That is, there are no portions of the wear plate 600 that areconnected to the remainder of the wear plate 600 only by narrowsections.

A wear plate 620 shown in FIG. 27b has similar features to the wearplate 600 of FIG. 27a , but has different pattern of varying dimensioneddebris slots. A first set of longitudinal debris slots 624 are generallyrectangular with rounded corners, similar to the debris slots describedand illustrated above, and are located centrally between the lateralsides 626 of the wear plate 620. A second set of peripheral debris slots628 extend adjacent to the lateral sides 626 of the wear plate 620. Eachof the peripheral debris slots 628 has a longitudinal portion 632extending along a similar direction as the longitudinal debris slots624, and a lateral portion 636 that deviates from the longitudinalportion 632 and extends along the travel direction dt of the belt. Ithas been found that, in some cases, debris travels down the lateralsides of the endless belts and gets underneath between the endless beltand the wear plates. The peripheral debris slots 628, and their lateralportions 636 in particular, assist in quickly flushing away this debristo reduce its chances of lingering between the endless belt and the wearplate 600.

FIG. 28 shows locating features of a wear plate 700 and an edge guide704 that assist with maintaining the correct alignment of the wearplates 700 while enabling them to expand and contract as a result offluctuations in the operating temperature. The wear plates 700 havelocating slots 708 along their lateral edges. The edge guide 704 is madeof 14 gauge stainless steel that has a curved profile, enabling it to bedeflected as the wear plates 700 are being positioned. Locating tabs 712of the edge guide 704 mate with the locating slots 708 of the wearplates 700. The size of the locating tabs 712 and the locating slots 708are selected to enable the wear plates 700 to expand and contract.

FIGS. 29a and 29b are top perspective views of a debris deflector 800for a conveyor system in accordance with another embodiment. The debrisdeflector 800 acts much like the debris deflector 98 of FIG. 4 or thedebris deflector 198 of FIG. 5, and provides a barrier to protect lowerreturn portion of an endless belt from debris falling from the supportdeck that supports an upper conveying portion of the endless belt, inparticular where the support deck is provided in the form of the modulargrid panels. The debris deflector 800 is generally mounted on an angledirected downwardly towards the longitudinal centerline of the serviceline. A debris deflection surface 804 of the debris deflector 800 istypically planar and performs the task of catching and directing debristowards a longitudinal centerline of the service line as a result of thedebris deflector 800 being mounted on an angle, with an upper end 808 ofthe debris deflection surface 804 being elevated above a lower end 812thereof. Two debris guides 816 extending between the upper end 808 andthe lower end 812 direct debris towards the lower end 812 (that is, theelimination end of the debris deflector 800 towards which debrismigrates primarily as a result of gravity). The debris deflector 800 hasa mounting tab 820 towards and recessed from the upper end 808, and anangled flange 824 towards and recessed from the lower end 812. Theangled flange 824 has a mounting slot 828 that is generally parallel tothe plane of the debris deflection surface 804.

The debris deflector 800 is formed from a single piece of aluminum, butmay be formed from other suitable materials, such as galvanized steel,stainless steel, molded plastic, fiberglass, etc.

As will be readily understood, while the debris deflector 800 is shownhaving a particular configuration, the debris deflector 800 can also bemade so that it is a mirror image of the debris deflector illustrated inFIGS. 29a and 29 b.

FIGS. 30a and 30b shows a lateral bracket support 832 for use with thedebris deflector 800. A plurality of lateral bracket supports 832 extendalong the longitudinal length of the service line, coupled to the twoinner support rails and two outer support rails, thereby forming lateralframes for supporting various components. The inner support rails aregenerally positioned symmetrically about the longitudinal centerline ofthe service line, while the two outer support rails are situatedproximal to the longitudinal walls of the trench. The lateral bracketsupports 832 forming the inner support rails and the outer support railsmay be fixedly attached in place by rivets, threaded fasteners (e.g.,bolts), metallurgic bonding (e.g., welded attachment), or any othersuitable means to achieve a secure attachment.

The lateral bracket support 832 has a set of pins 836 along its topsurface for engaging the support rails. A support face 840 that sitsgenerally vertically when the lateral bracket support 832 is installedhas a pair of bracket support slots 844 for supporting a mountingbracket. The bracket support slots 844 have a wider upper portion 848and a narrower lower portion 852.

A mounting bracket 856 for use with the lateral bracket support 832 isshown in FIGS. 31a and 31b . The mounting bracket 856 is die-formed froma single sheet of galvanized steel, but can also be formed of anothersuitable material, such as stainless steel, aluminum, injection-moldedplastic, etc. A generally planar main plate 860 of the mounting bracket856 is reinforced against flexure via a reinforcement flange 864. Themounting bracket 856 has a pair of connector tabs 868 that extend fromand parallel to the main plate 860 of the mounting bracket 856 at theirends, resulting in a gap 872 between the connector tabs 868 and the mainplate 860. A locking tab 876 is positioned below the connector tabs 868,and, in an undeployed state, is co-planar with the main plate 860. Aforming slot 880 is positioned towards the end of the locking tab 876,and a flexure slot 884 is positioned at the base of the locking tab 876.

Two horizontally oriented tab slots 888 are positioned side-by-sidebelow the locking tab 876. Below the two tab slots 888 are two debrisdeflector securement tabs 892 that have been deflected to extendorthogonally to the main plate 860 of the mounting bracket 856. A returnroller assembly pass-through 894 is positioned under the two debrisdeflector securement tabs 892.

A return roller assembly slot 896 is positioned towards a lower end ofthe mounting bracket 856. The return roller assembly slot 896 is widerat its upper end 900 and narrows towards its lower end 904. A returnroller assembly rest 908 is formed from a deflected tab at the bottom ofthe return roller assembly slot 896 and has a pin through-hole 912extending through it.

The connecting and securing of the mounting bracket 856 to the lateralbracket support 832 is shown in FIGS. 32a to 32f . Once the lateralbracket supports 832 are secured on both sides of the trenches, themounting brackets 856 can be secured to them along a first side. In FIG.32a , the connector tabs 868 of the mounting bracket 856 are shown beingaligned with the bracket support slots 844 of the lateral bracketsupport 832. The mounting bracket 856 is oriented so that the debrisdeflector securement tabs 892 extend towards the corresponding opposinglateral bracket support 832. Where the lateral bracket support 832 iscoupled to one of the outer support rails, the mounting bracket 856 isoriented so that the connector tabs 868 extend to the adjacent innersupport rail, and vice versa. The connector tabs 868 are then insertedthrough the wide upper portion 848 of the bracket support slots 844, asshown in FIG. 32b . Once the connector tabs 868 are inserted through thebracket support slots 844, the mounting bracket is slid downwards sothat the connector tabs 868 pass through the narrower lower portion 852of the bracket support slots 844, as shown in FIG. 32c . In thisposition, the connector tabs 868 engage the support face 840 of thelateral bracket support 832. A flat-head screwdriver 916 is theninserted into the forming slot 880 of the locking tab 876 as shown inFIG. 32d , and the handle of the flat-head screwdriver 916 is pivotedupwards to deflect the locking tab 876 under the bottom of the lateralbracket support 832 as shown in FIGS. 32e and 32f . The flexure slot 884decreases the force required to deflect or bend the locking tab 876.Once the locking tab 876 is deflected under the bottom of the lateralbracket support 832, upward travel of the mounting bracket 856 isprevented, thus constraining the locking tabs 868 to the narrower lowerportion of the bracket support slots 844 that prevent their exit toeffectively lock the mounting bracket 856 in place relative to thelateral bracket support 832.

FIGS. 33a to 33e show the installation and securing of the debrisdeflector 800 to the mounting brackets 856. A first of the mountingbrackets 856 a is secured to a lateral bracket support 832 coupled tothe outer support rail. The debris deflector 800 is then positioned suchthat a corresponding one of the debris deflector securement tabs 892 ofthe mounting bracket 856 a that is secured to the lateral bracketsupport 832 is inserted through the mounting slot 828 of the debrisdeflector 800, as is shown in FIG. 33 b.

While not shown, a second debris deflector 800 that is a mirror image ofthe shown debris deflector 800 is also positioned to insert the otherdebris deflector securement tab 892 of the mounting bracket 856 athrough the mounting slot 828 of the second debris deflector 800.Adjacent debris defectors 800 abut to provide sealing contact betweenthem, thereby constraining debris to be caught by one of the two debrisdeflectors 800. The longitudinal length of the debris deflectors 800 isselected such that two debris deflectors 800 span longitudinally betweeneach pair of mounting brackets 856 secured to a corresponding pair ofinner lateral support rails and outer support rails and provide acontiguous arrangement to protect the return portion of the endless beltfrom debris falling from above; that is, from or around the uppertransport portion of the endless belt.

The mounting tab 820 of each of the two debris deflectors 800 are theninserted into a corresponding one of the tab slots 888 of the mountingbracket 856 b that is not yet attached to the other lateral bracketsupport 832, as is shown in FIG. 33c . The mounting tabs 820 of thedebris deflectors 800 extending through the tab slot 888 are deflectedas shown in FIGS. 33d and 33e to restrict movement of the debrisdeflectors 800 relative to the mounting brackets 856 a, 856 b. Thesecond mounting bracket 856 b is then secured to the second lateralbracket support 832 as is shown in FIGS. 32a to 32 f.

It will be understood that one of the lateral bracket supports 832 canbe constructed to have the same features as the mounting brackets 856,and that the debris deflector 800 can be coupled towards one end to thelateral bracket support 832 directly and to a mounting bracket 856towards the other end before the mounting bracket 856 is secured to theother lateral bracket support 832.

While the mounting brackets 856 and the debris deflector 800 are shownhaving single tabs and slots to enable them to be coupled together,other types of projections and apertures can be employed to couple them.For example, multiple projections such as tabs, pins, etc. can beemployed to engage with corresponding slots, pin-holes, etc.

FIG. 34 is an isometric view of a debris deflector 1400 in accordancewith a further embodiment. The debris deflector 1400 is similar to thedebris deflector 800 of FIGS. 29a and 29b . The debris deflector 1400 isgenerally mounted on an angle directed downwardly towards thelongitudinal centerline of the service line. A debris deflection surface1404 of the debris deflector 1400 performs the task of catching anddirecting debris towards a longitudinal centerline of the service lineas a result of the debris deflector 1400 being mounted on an angle. Thedebris deflection surface 1404 is generally planar, but has a watercollection portion 1406 that is angled up to deflect water travellinggenerally downwards to wash across the debris deflection surface 1404. Asupport tab 1407 is bent downwards to support an upper end 1408 of thedebris deflection surface 1404, which is elevated above a lower end 1412thereof. Two debris guides 1416 extending between the upper end 1408 andthe lower end 1412 direct debris towards the lower end 1412 (that is,the elimination end of the debris deflector 1400 towards which debrismigrates primarily as a result of gravity). The debris deflector 1400has a mounting tab 1420 towards and recessed from the upper end 1408,and an angled flange 1424 towards and recessed from the lower end 1412.The angled flange 1424 has a mounting slot 1428 that is generallyparallel to the plane of the debris deflection surface 1404.

The debris deflector 1400 is formed from a single piece of aluminum, butmay be formed from other suitable materials, such as galvanized steel,stainless steel, molded plastic, fiberglass, etc.

As will be readily understood, while the debris deflector 1400 is shownhaving a particular configuration, the debris deflector 1400 can also bemade so that it is a mirror image of the debris deflector illustrated inFIG. 34.

FIGS. 35a to 35c show a return roller assembly 920 in accordance withanother embodiment. The lower return portion of the endless belt issupported by a plurality of return roller assemblies 920 so thatstretching of the endless belt is mitigated along the lower returnportion. Stretching of the endless belt causes fatigue in the componentsof the endless belt, particularly the pins that couple the links of theendless belt together. While the return roller assemblies 920 lie belowthe debris deflectors 800, they are still subjected to a dirty and wetenvironment. It is desirable to inhibit the migration of debris into thereturn roller assemblies, as it can increase wear between componentsthat move against other components, such as the bearing members uponwhich the roller wheels are mounted and the shaft on which the bearingmembers rotate in the example shown.

The return roller assembly 920 includes a shaft 924 defining an axis CAand having a first shaft end 933 and a second shaft end 935. A firstbearing member 928 is rotatably mounted on the shaft 924. The firstbearing member 928 has a central bearing member portion 932, upon whichis mounted a roller wheel 940 for rotatably supporting the lower returnportion of the belt 36. The first bearing member 928 further has a firstlateral bearing member portion 936 extending axially from the centralbearing member portion towards the first shaft end 933, and a secondlateral bearing member portion 937 extending axially from the centralbearing member portion towards the second shaft end 935.

The return roller assembly 920 further includes a first bearing membersleeve structure 941 extending from the first bearing member 928 towardsthe first shaft end 933. The first bearing member sleeve structure 941is sealingly mounted to the first lateral bearing member portion 936. Inthe example shown, the first bearing member sleeve structure 941 ismounted to the first lateral bearing member portion 936 with a firstbearing member sleeve structure sealing member 960 therebetween so as toseal against leakage therebetween. The first bearing member sleevestructure sealing member 960 is, in the example shown, an O-ring,however it could be any other suitable type of sealing member such as anX ring, or a U ring. This sealing engagement prevents the migration ofcontaminants into the interface between the inner surface of the firstbearing member 928 and the outer surface of the shaft 924 through theinterface between the first bearing member sleeve structure 941 and thefirst lateral bearing member portion 936.

The first bearing member sleeve structure 941 has a shaft engagementsurface 945 that is rotatably engaged with the shaft 924 at a point thatis laterally outboard of the first bearing member 928 towards the firstshaft end 933. This shaft engagement surface 945 assists in inhibitingthe migration of contaminants along the to the aforementioned interfacebetween the inner surface of the first bearing member 928 and the outersurface of the shaft 924. The shaft engagement surface 945 can beconsidered to be a sacrificial surface in order to protect theaforementioned interface.

The first bearing member sleeve structure 941 may be made up of severalseparate elements, including a flange bushing 948, a reducer 964 and afiller sleeve 956 in the reducer 964. The flange bushing 948 has theshaft engagement surface 945 thereon, and includes a flange 952 whichabuts an end of the filler sleeve 956 so as to hold the filler sleeve956 in place against the central bearing member portion 932 and theroller wheel 940. The inner surface of the filler sleeve 956 is thesurface of the first bearing member sleeve structure 941 that issealingly engaged with the first lateral bearing member portion 936.This arrangement ensures that there is a spacing between the firstbearing member 928 and the flange bushing 948. The reducer 964, whichhas the filler sleeve 956 therein has an internal ridge 968 that abutsthe same end of the filler sleeve 956 as is abutted by the flangebushing 948. The reducer 964 includes a laterally outer portion 972 anda laterally inner portion 973. The laterally outer portion 972 has agreater inner diameter than does the laterally inner portion 973 andoverlaps axially with the first shaft sleeve structure 941 and is spacedradially from the first shaft sleeve structure 941.

As a result, when dirt, water and other contaminants get into the spaceinside the laterally outer portion 972, they are discouraged fromreaching the laterally inner portion because of the change in diameterat that point.

The first bearing member sleeve structure 941 rotates with the firstbearing member 928 on the shaft 924. In an alternative embodiment, thereducer 964, the filler sleeve 956 and the flange bushing 948 may all beformed directly from a single element.

The return roller assembly 920 further includes a first shaft sleevestructure 943 fixedly and sealingly mounted to the shaft 924 laterallyoutboard towards the first shaft end 933 relative to the shaftengagement surface 945 of the first bearing member sleeve structure 941.

The first shaft sleeve structure 943 is sealingly mounted to the shaft924 with a first shaft sleeve structure sealing member 992 therebetweenso as to provide sealing engagement therebetween. The first shaft sleevestructure sealing member 992 may be an o ring, a U ring, an X ring orany other suitable kind of sealing member. The sealing member 992prevents migration of contaminants between the shaft 924 and the firstshaft sleeve structure 943 towards the first bearing member sleevestructure 941.

The first shaft sleeve structure 943 may be formed from a plurality ofcomponents including a seal sleeve 988 and a deflector sleeve 996. Theseal sleeve 988 is mounted on the shaft 924 and has an inner surfacethat is the surface of the first shaft sleeve structure 943 that issealingly engaged with the shaft 924. The flanged deflector sleeve 996is mounted atop of the seal sleeve 988 and may be bonded thereto.

A thrust washer 976 is positioned in abutment with the flange bushing948, and may rotate together with the first bearing member sleevestructure 941. A steel washer 980 and a rubber washer 984 are mounted onthe shaft 928 adjacent the thrust washer 976. The seal sleeve 988 andthe flanged deflector sleeve 996 abut (i.e. the first shaft sleevestructure 943 abuts) the adjacent rubber washer 984.

An orientation retention feature in the form of a projection extendsorthogonal to the axis of the return roller assembly 920. In thisparticular embodiment, the projection is a slotted spring pin 1000 thatis inserted through through-holes in the seal sleeve 988 and the shaft924 and extends out of the seal sleeve 988 generally radially. The pin1000 has an enlarged head that prevents full passage thereof through theseal sleeve 988. The pin 1000 holds the axial position of the firstshaft sleeve structure 943, such that the first shaft sleeve structure943 presses with sufficient force against the rubber washer 984, whichin turn presses against the steel washer 980, which in turn pressesagainst the thrust washer 976. In other embodiments, the return rollerassembly 920 can have other orientation retention features towards itsfirst shaft end 933, such as, for example, a non-circular profile madeby or example, crimping, or other types of projections, such as, forexample, a coiled spring pin or tabs.

The rubber washer 984 is a non-rotating component as it remainsfrictionally engaged with the first shaft sleeve structure 943. Thesteel washer 980 is non-rotating due to frictional engagement with therubber washer 984.

The first bearing member sleeve structure 941 has a first rotationinterface sealing surface (which is the surface shown at 976 a on thethrust washer 976) and the first shaft sleeve structure 943 has a secondrotation interface sealing surface (which is the surface shown at 984 aon the steel washer 980). The first and second rotation interfacesealing surfaces 976 a and 984 a extend radially and circumferentiallyand engage one another to seal against migration of contaminantstherebetween. The first shaft sleeve structure 943 urges the first andsecond rotation interface sealing surfaces 976 a and 984 a intoengagement with one another.

As the seal sleeve 988 also is sealed against the shaft 924 via theO-ring 992, the wheel bushing 928 is sealed, inhibiting the migration ofcontamination between the wheel bushing 928 and the shaft 924.

The return roller assembly 920 further includes a second bearing membersleeve structure 944 extending from the first bearing member 928 towardsthe second shaft end 935. The second bearing member sleeve structure 944is sealingly mounted to the second lateral bearing member portion 937via a sealing member therebetween, such as an o ring, a U ring, an Xring or any other suitable sealing member so as to prevent the migrationof contaminants therebetween.

In the example shown, the bearing member 928 and the roller wheel 940are a first bearing member 928 (and are also identified in FIGS. 35a and35b at 928 a) and a first roller wheel 940 respectively. The returnroller assembly 920 further comprises a second bearing member 928 (shownindividually at 928 b) rotatably mounted on the shaft 924, closer to thesecond shaft end 935 than is the first bearing member 928, and having acentral bearing member portion 932 upon which is mounted a second rollerwheel 940 for rotatably supporting the conveyor belt, a first lateralbearing member portion 936 extending axially from the central bearingmember portion 932 towards the second shaft end 935, and a secondlateral bearing member portion 937 extending axially from the centralbearing member portion towards the first shaft end 933. The returnroller assembly 920 further comprises a first bearing member sleevestructure 941 for the second bearing member 928 b, extending from thesecond bearing member 928 b towards the second end 935, and sealinglymounted to the first lateral bearing member portion 936 of the secondbearing member 928 b, and having a shaft engagement surface 945 that isrotatably engaged with the shaft 924. The return roller assembly 920further comprises a second bearing member sleeve structure 941 for thesecond bearing member, extending from the second bearing member 928 btowards the first shaft end 935. The second bearing member sleevestructure 941 for the second bearing member 928 b is sealingly mountedto the second lateral bearing member portion 937 of the second bearingmember 928 b. The return roller assembly 920 further comprises a secondshaft sleeve structure 943 fixedly and sealingly mounted to the shaft924 laterally outboard towards the second shaft end 935 relative to theshaft engagement surface 945 of the first bearing member sleevestructure 941 of the second bearing member 928 b.

The first bearing member sleeve structure 941 for the second bearingmember 928 b has a first rotation interface sealing surface (provided ona thrust bushing) and the second shaft sleeve structure 943 has a secondrotation interface sealing surface (provided on a steel washer), and arubber washer may be provided between the steel washer and a surface ofthe second shaft sleeve structure 943. The first and second rotationinterface sealing surfaces 976 a and 980 a on the first bearing membersleeve structure 941 for the second bearing member 928 b and the secondshaft sleeve structure 943 extend radially and circumferentially andengage one another to seal against migration of contaminantstherebetween. The second shaft sleeve structure 943 urges the first andsecond rotation interface sealing surfaces 976 a and 980 a intoengagement with one another

The first and second shaft sleeve structures 943 may be mirror images ofone another but may be similar to one another aside from that. A pin1000 may be provided at the second shaft end 935 to hold the secondshaft sleeve structure 943 in similar manner to the pin 1000 at thefirst shaft end 933 for the first shaft sleeve structure 943. The firstand second bearing member sleeve structures 941 may be similar to oneanother aside from being mirror images of one another.

The return roller assembly 920 further includes a second bearing membersleeve structure 944 extending from the second bearing member 928 btowards the second shaft end 935. The second bearing member sleevestructure 944 is sealingly mounted to the second lateral bearing memberportion 937 of the second bearing member 928 b via a sealing membertherebetween, such as an O-ring, a U-ring, an X-ring or any othersuitable sealing member so as to prevent the migration of contaminantstherebetween. In the example shown, the second bearing member sleevestructure 944 for the second bearing member 928 b is contiguous andintegral with the second bearing member sleeve structure 944 for thefirst bearing member 928 a.

FIGS. 36a and 36b show the toolless installation of the return rollerassembly 920 between two mounting brackets 856 a, 856 b. In order toinstall the return roller assembly 920 between the two mounting brackets856 a, 856 b that are secured to lateral bracket supports 832 ofadjacent inner and outer lateral support rails, the return rollerassembly 920 is angled to enable one end thereof to be inserted into theupper end 900 of the return roller assembly slot 896 of one of themounting brackets 856. The upper end 900 of the return roller assemblyslot 896 is large enough to receive the end section 972 of the reducer964, enabling the return roller assembly 920 to be inserted far enoughto permit the other end of the return roller assembly 920 to be insertedinto the return roller assembly slot 896 of the other mounting bracket856. Once the return roller assembly 920 is positioned in the returnroller assembly slots 896 of both mounting brackets 856, the returnroller assembly 920 is shifted so that the reducers 964 are positionedbetween the mounting brackets 856, allowing the seal sleeves 988 toslide into the lower ends 904 of the return roller assembly slots 896 ofthe mounting brackets 856 a, 856 b. The return roller assembly 920 isconstructed so that ends 1004 of the reducers 964 and the flangeddeflector sleeve 996 abut against the main plates 860 of the mountingbrackets 856 a, 856 b next to the lower ends 904 of the return rollerassembly slots 896. The pins 1000 of the return roller assemblies 920are aligned with and inserted into the pin through-holes 912 of thereturn roller assembly rests 908 which support the seal sleeves 988. Aswill be appreciated, the pins 1000 both limit relative movement of theseal sleeves 988 and the shaft 924 and inhibit rotation of the returnroller assembly 920 in the return roller assembly slots 896.

FIGS. 37a and 37b show a wear plate 1008 for a conveyor system inaccordance with another embodiment. The wear plate 1008 is similar indesign to the wear plate 88 shown in FIGS. 17a and 17b , having debrisslots 1012 allowing debris between the wear plate 1008 and an endlessbelt positioned thereon to be carried away via a fluid. A leading edge1016 and a trailing edge 1020 of the wear plate 1008 are oblique to adirection of travel dt of an endless belt.

Traditionally, wear plates are beveled along at least their trailingedges and sometimes along their leading edges as sharp deflectingsurfaces of the wear plate structure can significantly decrease thelifespan of the endless belt. The wear plates are secured to a structurevia countersunk fasteners such as screws or bolts. As the wear platesare worn, however, the head of the fasteners are eroded, making itdifficult to remove the fasteners when it is time to replace the wearplates.

The wear plate 1008 provides a plate mount 124 for securing the wearplate 1008 to a support structure. The wear plate 1008 is typicallystainless steel, but can be any other suitable material that resistswear and that is sufficiently ductile to be permanently and stablydeformable via application of a deforming force without significantlyimpacting the structural strength of the wear plate 1008. Other suitablematerials include, for example, galvanized steel.

The plate mount 1024 is formed within the wear plate 1008 by lasercutting a design of at least one cut in the wear plate 1008 or by anyother suitable means. In particular, the plate mount 1024 of the wearplate 1008 includes a fastener retainer 1028 having a retention hole1032 extending through the wear plate 1008. Two cuts 1036 define aretainer support 1040 connecting the fastener retainer 1028 to theremainder of the wear plate 1008. As used herein, a retainer support isany structure connecting the fastener retainer to the rest of the wearplate and which is permanently deformable to enable the retention holeto be depressed relative to the rest of the wear plate.

Two flexure apertures 1044 are cut in the retainer support 1040 tofacilitate deformation of the plate mount 1024. While in the describedembodiment, the fastener retainer is an annular structure surrounding aretention hole through which a bolt, screw, etc. is inserted, in otherembodiments, the fastener retainer can be any other shape or design forretaining a fastener for securing the wear plate.

FIGS. 38a and 38b show the wear plate 1008 after deformation of theplate mount 1024. The plate mount 1024 can be deformed via machine ormanually during manufacturing, any time prior to installation, or at thetime of installation. As shown, the plate mount 1024 is deformedsufficiently so that a variety of fasteners, such as hex bolts, can beemployed to secure the wear plate 1008 to a support structure underneaththe wear plate wherein a fastener 1048 is sunk below a top surface ofthe wear plate 1008, as is shown in FIG. 39.

FIG. 40 shows a wear plate anchor 1052 for use with the wear plate 1008.The wear plate anchor 1052 is die formed from a single sheet of steeland has a longitudinal body 1056 with a through-hole 1060 forpass-through of a shank of a fastener. A pair of flanges 1064 extendfrom the longitudinal body 1056 on either side of the through-hole 1060defining a channel 1068 therebetween. An orientation locking tab 1072extends in a direction generally opposite of the direction in which theflanges 1064 extend. The channel 1068 is dimensioned to engage the sidesof a nut to prevent it from turning.

FIGS. 41a to 41d show the installation process of the wear plate 1024 ofFIGS. 38a and 38b using the wear plate anchor 1052 of FIG. 40. Afastener 1048 such as a bolt is inserted through the retention hole 1032of the plate mount 1024, passed through the through-hole 1060 of thewear plate anchor 1052, and inserted and threaded in a nut 1076 tosecure it thereto. Preferably, the plate mount 1024 is formed so thatthe fastener retainer 1028 is depressed sufficiently to fully recess ahead of the fastener 1048 below a maximum wear level of the wear plate1008, as shown in FIG. 39. The wear plate 1008 is then positioned on asupport deck that is made from a set of modular grid panels having a setof longitudinal cross-members 1080, as is shown in FIG. 41a with thewear plate anchor 1052 being inserted between adjacent longitudinalcross-members 1080. The length of the bolt 1048 is selected so that thelongitudinal body 1056 of the wear plate anchor 1052 depends below thelongitudinal cross-members 1080, but the orientation locking tab 1072 isstill positioned between the longitudinal cross-members 1080. The headof the bolt 1048 is then turned, and the wear plate anchor 1052 turnswith it until the orientation locking tab 1072 engages one of thelongitudinal cross-members 1080, thus restricting the wear plate anchor1052 from rotating further, as shown in FIGS. 41c and 41d . Thereafter,continued rotation of the bolt 1048 causes the nut 1076 to travel up theshank of the bolt 1048, thereby clamping the wear plate anchor 1052against the bottom surface of the longitudinal cross-members 1080.

The head of the bolt 1048 securing the wear plate 1008 via the platemount 1024 can thus be sufficiently recessed so that it is stillrotatable via a tool when the wear plate 1008 is worn to the point ofneeding replacement. In order to remove the wear plate 1008, the bolt1048 is turned in an opposite direction (typically counterclockwise).The orientation locking tab 1072 is rotated until it abuts against anopposite longitudinal cross-member 1080, thus restricting furtherrotation of the wear plate anchor 1052. Further rotation of the bolt1048 causes the nut 1076 to travel down the shank until the wear plateanchor 1052 can be sufficiently rotated to withdraw it between thelongitudinal cross-members 1080.

FIGS. 42a and 42b show a wear plate 1084 in accordance with a furtherembodiment having a set of plate mounts 1088, each formed from a set ofthree spiral or circumvoluted cuts 1090 extending from a fastenerretainer 1091 having a retention hole 1092. The circumvoluted cuts 1090define a retainer support 1094 extending from the fastener retainer 1091to a remainder 1095 of the wear plate 1084. In this embodiment, theplate mounts 1088 are cut during manufacturing, but fastener retainer isnot depressed prior to installation.

During the installation process, a bolt is inserted through theretention hole 1092 and threadedly secured either indirectly to a gridpanel of the support deck via an anchor of some sort, such as the wearplate anchor 1052 of FIG. 40, or directly to a grid panel. FIG. 42cshows a bolt 1095 having been inserted through the retention hole 1092and the wear plate anchor 1052, and threadedly secured within the nut1076.

As the bolt 1095 is tightened, the force on the fastener retainer 1091causes the deformation of the circumvoluted cut retainer support 1094,urging the retainer support 1094 to extend in the direction of the pointto which the bolt 1095 is secured (that is, the nut 1076 adjacent thethrough-hole 1060 of the wear plate anchor 1052), as is shown in FIGS.42d and 42 e.

As will be understood, by using circumvoluted cuts 1090 to define theretainer support 1094, the retainer support 1094 deforms through theforce applied by the head of the bolt 1095 against the fastener retainer1091.

FIGS. 43a and 43b show a plan view of a belt drive assembly 1096 for anendless belt in accordance with an embodiment. The belt drive assembly1096 includes a drive motor 1100 having a transmission 1104 extendingtherefrom. The transmission 1104 includes a right-angle gear box toredirect torque from the drive motor 1100. A drive coupler 1106 iscoupled to each side of the transmission 1104, and a drive member in theform of a drive shaft 1108 is coupled to each drive coupler 1106 at aproximal end of the drive shaft 1108. Each of the drive shafts 1108 ispivotally coupled at a remote end thereof at a pivot point 1112. A setof sprockets 1116 are mounted on the drive shafts 1108 to engage anddrive the endless belt. A set of sprockets 1116 are mounted on the driveshaft 1108 and engage an endless belt 1122 to drive it.

FIG. 43c shows a drive member of the transmission in the form of aslotted sleeve 1123 that couples to the drive coupler 1106. The slottedsleeve 1123 has an aperture 1123 a having a key slot 1123 b.

FIGS. 44a, 44b , and 45 show the drive coupler 1106 in greater detail.The drive coupler 1106 includes a transmission connector 1124 having atransmission coupler 1125 with an alignment post recess 1128 forreceiving an alignment post extending from the transmission 1104. A key1132 on the outer surface of the transmission coupler 1125 enablestransmission of a torque force about a transmission rotation axis RATfrom the drive motor 1100 via the slotted sleeve 1123 of thetransmission 1104 of FIG. 43c that fits over the transmission connector1124. A resilient compressible ring 1136 interfaces with the slottedsleeve to accommodate irregularity between the rotation of thetransmission coupler 1125 and the slotted sleeve. A drive shaft bore1140 extends into an opposite side of the transmission coupler 1125. Aspherical bearing 1144 positioned inside of the transmission connector1124 has a recess for securely receiving a round drive post extendingfrom an adjacent end of the drive shaft 1108, and is positioned at theintersection of the transmission rotation axis RAT and a drive shaftrotation axis RADS. The spherical bearing 1144 generally fixes therotation axis of the drive shaft 1108 relative to the rotation axis ofthe transmission connector 1124 even when there is angular displacementbetween the rotation axes; that is, when the drive shaft rotation axisRADS is non-coaxial with the transmission rotation axis RAT. In thisembodiment, the spherical bearing 1144 is positioned in an at leastpartial spherical socket within the transmission connector 1124. Alubrication port 1148 enables lubrication of the socket in which thespherical bearing 1144 resides.

A first flange 1152 of the transmission connector 1124 is secured via aset of bolts 1153. A set of large bores 1154 adjacent thecircumferential periphery of the first flange 1152 accommodates a set ofresilient compressible bushings 1155.

A drive shaft connector 1156 includes a second flange 1157 is separatedfrom the first flange 1152 via a resilient compressible spacer 1160 thatis positioned between a first connector face 1157 of the first flange1152 and a second connector face 1158 of the second flange 1157. Thecompressible spacer 1160 permits the first and second connector faces1157, 1158 to be non-parallel to one another while being securelycoupled to one another. The drive shaft connector 1156 is rotationallycoupled to the transmission connector 1124 via a set of bolts 1164 thatis inserted through bolt holes 1212 in the second flange 1157, throughthe resilient compressible bushings 1155 of the first flange 1152, andsecured with nuts 1165. The resilient compressible bushings 1155 and theresilient compressible spacer 1160 permit the transmission connector1124 and the spherical bearing 1144 to be connected together with thefirst and second connector faces 1157, 1158 being non-parallel to oneanother. Rotation of the transmission connector 1124 causes the bolts1164 to exert a torque force on the drive shaft connector 1156 tothereby cause it to rotate.

The second flange 1157 has a square-profiled through-hole 1168 that isdimensioned to correspond to the cross-section profile of the driveshafts 1108. A resilient compressible sealing ring 1172 that has aslightly smaller profiled through-hole than the through-hole of thesecond flange 1157. That is, the resilient compressible sealing ring1172 extends slightly over the square-profiled through-hole 1168. Aretainer annulus 1176 encloses and covers all but the resilientcompressible sealing ring 1172 that extends over the square-profiledthrough-hole 1168. A locking flange 1180 having a generally circularpass-through aperture 1184 is releasably securable to the second flangevia a set of bolts 1188 that pass through the retainer annulus 1176.Four notches 1192 are evenly spaced along the periphery of the generallycircular pass-through aperture 1184. In addition, four grips 1196 areevenly spaced about the periphery of the locking flange 1180.

Referring now to FIGS. 45 and 46 a to 46 c, one of the drive couplers1106 is shown being connected to one of the drive shafts 1108. As can beseen in FIG. 46a , the drive shaft 1108 has four circumferentiallyextending slots 1200 cut through the edges of its square profile closeto an end of the drive shaft 1108 that will engage the drive coupler1106. In addition, the edges 1204 of the drive shaft 1108 are beveledalong a length of the drive shaft commencing at the end of thesquare-profiled section of the drive shaft 1108 and extending past thefour circumferentially extending slots 1200.

During coupling of the drive coupler 1106 with the drive shaft 1108, allbut one of the bolts 1164 coupling the two flanges 1152, 1157 together,is removed. The one bolt 1164 retains the second flange 1157 connectedto the first flange 1152. Removal of the other bolts 1164 enables moreplay between the first and second flanges 1152, 1157. Further, all ofthe bolts 1188 coupling the locking flange 1180 to the second flange1157 are removed.

The locking flange 1180 is then slipped over the drive post of the driveshaft 1108 and the four notches 1192 are aligned with the four edges1204 of the end of the drive shaft 1108. The four notches 1192 of thelocking flange 1180 are dimensioned to snugly receive the four bevelededges 1204 of the profile of the drive shaft 1108. The locking flange1180 is slid along the drive shaft 1108 until it is positioned over thefour circumferentially extending slots 1200. Here, the circumferentiallyextending slots 1200 permit the locking flange 1180 to be slidableaxially along the end portion of the drive shaft 1108 when the lockingflange 1180 is in a first rotational position about the drive shaftrotation axis RADS, and that is rotatable from the first rotationalposition to a second rotational position about the drive shaft rotationaxis RADS to engage the plurality of circumferentially extending slots1200 thereby axially locking the locking flange 1180 with the driveshaft 1108.

The drive shaft 1108 is rotated until its profile is generally alignedwith the orientation of the square-profiled through-hole 1168 of thesecond flange 1157. A drive post 1206 of the drive shaft 1108 is theninserted into the spherical bearing 1144. The spherical bearing 1144snugly holds the drive post 1206. The square-profiled portion of thedrive shaft 1108 is then urged past the resilient compressible sealingring 1172 and into the square-profiled through-hole 1168 of the secondflange 1157 until the locking flange 1180 abuts against the retainerannulus 1176. The resilient compressible sealing ring 1172 fits snuglyabout the drive shaft 1108. The locking flange 1180 can then be rotatedas required on the surface of the circumferentially extending slots 1200of the drive shaft 1108 via the four grips 1196 until bolt holes 1208are aligned with corresponding bolt holes 1210 in the retainer annulus1176, and the bolts 1188 are then inserted into the bolt holes 1208 androtated until the locking flange 1180 is secured tightly to the retainerannulus 1176 and the second flange 1157. Once the locking flange 1180 issecured to the second flange 1157, the balance of the bolts 1164 areinserted into bolt holes 1212 and through the corresponding resilientcompressible bushings 1155 of the first flange 1152, and the nuts 1165are used to secure their ends on the opposite side of the first flange1152. When the nuts 1165 are tightened, there is a bit of play betweenthe first flange 1152 and the second flange 1157.

The drive couplers 1106 accommodate for angular misalignment between therotation axis of the drive shafts 1108 and the rotation axis of thedrive motor 1100. During installation of the belt drive assembly 1096,care is taken to align these rotation axes, but this can prove verychallenging. In the absence of the drive couplers 1106, even smallmisalignments between these rotation axes can cause mechanical failuresof the belt drive assembly 1096, such as sheared drive shafts.

The drive couplers 1106 enable torque to be transferred from the drivemotor 1100 to the drive shafts 1108 even when there is some misalignmentbetween the rotation axes of the drive motor 1100 and the drive shafts1108. As will be understood, angular misalignment of the rotation axesis accommodated by deformation of the resilient compressible spacer 1160separating the first and second flanges 1152, 1157, the resilientcompressible bushings 1155, and the resilient compressible sealing ring1172. The resilient compressible sealing ring 1172 is sufficiently firmto transfer torque from the transmission connector 1124 to the driveshaft 1108.

While, in the above-described embodiment, the drive shafts 1108 aresquare in cross-section, in other embodiments, the drive shafts can haveother non-circular cross-sectional shapes, such as, for example,hexagonal, ellipsoid, etc.

FIGS. 47a to 47c show a wear plate 1300 according to another embodiment.The wear plate 1300 is somewhat similar in construction to the wearplate 1008 shown in FIGS. 37a to 38b , and has a wear surface 1302 thatis positioned to incur wear. The wear plate 1300 is constructed of afirst material having a first electrical conductivity. For example, inthe illustrated embodiment, the wear plate 1300 is constructed ofstainless steel. The wear sensor includes a first electrical conduit1304 extending from an undersurface 1324 of the wear plate 1300 oppositethe wear surface 1302, and a second electrical conduit 1308 extendingfrom the undersurface 1324 adjacent the first electrical conduit 1304.In other embodiments, the electrical conduits can extend from a lateraledge of the wear plate. The electrical conduits 1304, 1308 arelike-dimensioned and each receives a plug 1312 from which extends a wire1316.

The wear plate 1300 has a gap 1320 in the first material around thefirst electrical conduit 1304. The gap 1320 extends in this case in aring around the first electrical conduit 1304 and has a depth extendingfrom the undersurface 1324 of the wear plate 1300. In the illustratedembodiment, the gap 1320 is filled with a second material having asecond electrical conductivity that is lower than the first electricalconductivity.

The wires 1316 are coupled to a voltage source in the form of a sensormodule 1328 coupled to an electrical source 1129, such as a battery oran electrical outlet. The sensor module 1328 includes an output devicein the form of a speaker, but can additionally or alternatively includea display, a network module, etc.

As discussed above, wear plates are meant to provide a sliding surfaceover which an endless belt is conveyed to transport a vehicle. Theendless belt is made of a plastic or other suitable material, and theweight of the vehicle being transported on the endless belt issignificant. As a result, the wear plates “wear”, being eroded by theendless belt over time.

The depth of the gap 1320 is selected to correspond to a wear platethickness at which a new wear plate 1300 should be ordered forreplacement or alternatively the depth of the gap 1320 is selected tocorrespond to a desired minimum wear plate thickness at which the wearplate 1300 should be replaced to ensure that undue damage is not causedto the endless belt traveling across the wear plate 1320 or to thesupport deck.

The sensor module 1328 either intermittently, regularly, or continuouslygenerates a voltage differential between the wires 1316 to cause anelectrical current to flow through the wires 1316 when they are coupledto the wear plate 1300 when in a first wear condition (i.e. thicker thanthe desired minimum wear plate thickness, or good operating condition),as is shown in FIG. 48a . When the wear plate 1300 is worn downsufficiently to a second wear condition (i.e., at least to the desiredminimum wear plate thickness as shown in FIG. 48b ), the electricalconduits 1304, 1308 are fully separated by a gap in the stainless steelof the wear plate 1300, but are held together by a second materialhaving the second electrical conductivity differing from the electricalconductivity of the stainless steel. The second material is a materialthat has a lower (and preferably insignificant) electrical conductivitythan that of the first material, and will maintain its connection to thesurrounding wear plate 1300 when the wear 1300 plate is in the secondwear condition. In the illustrated embodiment, the second material is anon-conductive epoxy, but can be any other suitable material for usewith the first material.

As a result of the full separation of the first electrical conduit 1304from the second electrical conduit 1308 through the first material, achange in electrical current flowing through the electrical conduits1304, 1308 is detected by the sensor module 1328. When the sensor module1328 determines that the change in electrical current flowing throughthe electrical conduits 1304, 1308 corresponds to a separation betweenthe electrical conduits 1304, 1308 through the stainless steel (based ona maintained drop in electrical current), the sensor module 1328 reportsthe condition by way of generating an audible signal or alert toindicate that the wear plate 1300 should be replaced.

During replacement of a wear plate 1300, the plugs 1312 are withdrawnfrom the electrical conduits 1304, 1308, and the worn out wear plate1300 is removed. The plugs 1312 are connected to the electrical conduits1304, 1308 of a new wear plate 1300, and it is secured in place.

While in this embodiment, the gap 1320 separating the first electricalconduit 1304 from the second electrical conduit 1308 is ring-shaped, inother embodiments, the gap 1320 can be other shapes to separateconnection of the electrical conduits 1304, 1308 through the firstmaterial having a first electrical conductivity when the wear plate 1300is sufficiently worn.

Instead of filling the gap with a second material, it may be left empty,in which case the first electrical conduit will be entirely disconnectedfrom the second electrical conduit when the wear plate is sufficientlyworn.

It will be appreciated that, although embodiments of the disclosure havebeen described and illustrated in detail, various modifications andchanges may be made. While preferred embodiments are described above,some of the features described above can be replaced or even omitted.Still further alternatives and modifications may occur to those skilledin the art. All such alternatives and modifications are believed to bewithin the scope of the disclosure.

1. A wear plate for use with a conveyor system, comprising: a platemount, having: a fastener retainer having a retention hole extendingthrough the wear plate; and a retainer support being defined by at leastone cut in the wear plate adjacent to and at least partially definingthe fastener retainer, the retainer support connecting the fastenerretainer to a main portion of the wear plate and enabling the fastenersupport to be depressed relative to a top surface of the wear plate. 2.A wear plate as claimed in claim 1, wherein the fastener retainer isdepressed via machine prior to installation of the wear plate.
 3. A wearplate as claimed in claim 1, wherein the fastener retainer isdepressable during tightening of a fastener inserted into the retentionhole and engaging a nut.
 4. A wear plate as claimed in claim 3, whereinthe at least one cut extends circumvolutely from the fastener retainer.5. A wear plate structure for use with a conveyor system, comprising: awear plate, at least a part of which is constructed from a firstmaterial having a first electrical conductivity, wherein the wear platehas a wear surface that is positioned to incur wear and an undersurfaceopposite the wear surface; and a first electrical conduit and a secondelectrical conduit which extend from the wear plate, wherein, when thefirst and second electrical conduits are connected to a voltage source,a first current flows between the first electrical conduit and thesecond electrical conduit through the first material when the wear plateis in a first wear condition, and current flow is reduced from the firstcurrent flow between the first electrical conduit and the secondelectrical conduit through the first material when the wear plate is ina second wear condition.
 6. A wear plate structure as claimed in claim5, wherein current flow is reduced to zero between the first electricalconduit and the second electrical conduit when the wear plate is in thesecond wear condition.
 7. A drive coupler, comprising: a first connectorcoupleable to a first drive member for torque transfer therebetween, thefirst drive member rotating about a first axis, the first connectorhaving a first connector face; a spherical bearing positioned in thefirst connector for receiving a second drive member that is rotatableabout a second axis, the spherical bearing being positioned at theintersection of the first and second axes; a second connector having asecond connector face, and being rotationally coupleable to the firstconnector for torque transfer therebetween, wherein the second connectoris coupleable to the second drive member for torque transfertherebetween; and a compressible spacer positioned between the firstconnector face and the second connector face, thereby permitting thefirst and second connector faces to be non-parallel to one another.
 8. Adrive coupler as claimed in claim 7, wherein an end portion of thesecond drive member has a non-circular cross-sectional shape, and has aplurality of circumferentially extending slots thereon, wherein thedrive coupler assembly further comprises a locking flange that has apass-through aperture having a profile that permits the locking flangeto be slidable axially along the end portion of the second drive memberwhen the locking flange is in a first rotational position about thesecond axis, and that is rotatable from the first rotational position toa second rotational position about the second axis to engage theplurality of circumferentially extending slots thereby axially lockingthe locking flange with the second drive member, wherein the lockingflange is connectable to the second connector.
 9. A return rollerassembly for use with a conveyor system, comprising: a shaft defining anaxis and having a first shaft end and a second shaft end; a bearingmember rotatably mounted on the shaft, and having a central bearingmember portion upon which is mounted a roller wheel for rotatablysupporting a lower return portion of a conveyor belt, a first lateralbearing member portion extending axially from the central bearing memberportion towards the first shaft end, and a second lateral bearing memberportion extending axially from the central bearing member portiontowards the second shaft end; a first bearing member sleeve structureextending from the bearing member towards the first shaft end, whereinthe first bearing member sleeve structure is sealingly mounted to thefirst lateral bearing member portion, wherein the first sleeve has ashaft engagement surface that is rotatably engaged with the shaft; asecond bearing member sleeve structure extending from the bearing membertowards the second shaft end, wherein the second bearing member sleevestructure is sealingly mounted to the second lateral bearing memberportion; and a first shaft sleeve structure fixedly and sealinglymounted to the shaft laterally outboard towards the first shaft endrelative to the shaft engagement surface of the first bearing membersleeve structure, wherein the first bearing member sleeve structure hasa first rotation interface sealing surface and the first shaft sleevestructure has a second rotation interface sealing surface, wherein thefirst and second rotation interface sealing surfaces extend radially andcircumferentially and engage one another to seal against migration ofcontaminants therebetween, wherein the shaft sleeve structure urges thefirst and second rotation interface sealing surfaces into engagementwith one another.
 10. A return roller assembly as claimed in claim 9,wherein the first bearing member sleeve structure is mounted to thefirst lateral bearing member portion with a first bearing member sleevestructure sealing member therebetween so as to provide sealingengagement therebetween, and wherein the first shaft sleeve structure issealingly mounted to the shaft with a first shaft sleeve structuresealing member therebetween so as to provide sealing engagementtherebetween.
 11. A return roller assembly as claimed in claim 9,wherein the first shaft sleeve structure is fixedly mounted to the shaftvia a first shaft sleeve mounting pin that passes through the firstshaft sleeve and the shaft.
 12. A return roller assembly as claimed inclaim 9, wherein the bearing member and the roller wheel are a firstbearing member and a first roller wheel respectively, and wherein thereturn roller assembly further comprises a second bearing memberrotatably mounted on the shaft, closer to the second shaft end than isthe first bearing member, and having a central bearing member portionupon which is mounted a second roller wheel for rotatably supporting theconveyor belt, a first lateral bearing member portion extending axiallyfrom the central bearing member portion towards the second shaft end,and a second lateral bearing member portion extending axially from thecentral bearing member portion towards the first shaft end, wherein thereturn roller assembly further comprises a first bearing member sleevestructure for the second bearing member, extending from the secondbearing member towards the second end, and sealingly mounted to thefirst lateral bearing member portion of the second bearing member, andhaving a shaft engagement surface that is rotatably engaged with theshaft, and wherein the return roller assembly further comprises a secondbearing member sleeve structure for the second bearing member, extendingfrom the second bearing member towards the first shaft end, wherein thesecond bearing member sleeve structure for the second bearing member issealingly mounted to the second lateral bearing member portion of thesecond bearing member, and wherein the return roller assembly furthercomprises a second shaft sleeve structure fixedly and sealingly mountedto the shaft laterally outboard towards the second shaft end relative tothe shaft engagement surface of the first bearing member sleevestructure of the second bearing member, wherein the first bearing membersleeve structure for the second bearing member has a first rotationinterface sealing surface and the second shaft sleeve structure has asecond rotation interface sealing surface, wherein the first and secondrotation interface sealing surfaces on the first bearing member sleevestructure for the second bearing member and the second shaft sleevestructure extend radially and circumferentially and engage one anotherto seal against migration of contaminants therebetween, wherein thesecond shaft sleeve structure urges the first and second rotationinterface sealing surfaces into engagement with one another.
 13. Areturn roller assembly as claimed in claim 9, wherein the first bearingmember sleeve structure includes a laterally outer portion and alaterally inner portion, wherein the laterally outer portion has agreater inner diameter than does the laterally inner portion andoverlaps axially with the first shaft sleeve structure and is spacedradially from the first shaft sleeve structure.
 14. A debris deflectorkit for use with a conveyor system, comprising: a debris deflectorconfigured to deflect debris that is falling from a conveyor belttowards an elimination end thereof, the debris deflector beingcoupleable towards a first end thereof to a first lateral frame portion;and a first mounting bracket engaging the debris deflector towards asecond end thereof opposite the first end of the debris deflector via afirst projection of one of the debris deflector and the first mountingbracket that is insertable through a first aperture in another of thedebris deflector and the first mounting bracket, the first mountingbracket being coupleable to a second lateral frame portion spaced fromthe first lateral frame portion.
 15. A debris deflector kit as claimedin claim 14, wherein the debris deflector is securable to the firstmounting bracket via bending of the projection extending out of theaperture.
 16. A return roller kit for use with a conveyor system,comprising: a return roller assembly having a rotation axis about whichrotates at least one roller wheel for supporting a conveyor belt along areturn path, the return roller assembly having a first orientationretention feature in a first end thereof.
 17. A return roller kit asclaimed in claim 16, wherein the first orientation retention featurecomprises a projection extending orthogonal to the rotation axis.
 18. Areturn roller kit as claimed in claim 16, further comprising: a firstmounting bracket having a first aperture and a first ledge adjacent tothe first aperture for supporting the first end of the return rollerassembly.
 19. A return roller kit as claimed in claim 16, wherein thereturn roller assembly has a second orientation retention feature in thesecond end thereof.
 20. A drive coupler assembly, comprising: a firstdrive member that is supported for rotation about a first axis by atleast a first bearing and a second bearing for the first drive member; asecond drive member that has a first end that is proximal to the firstdrive member and a second end that is distal to the first drive member,wherein the second end is supported by a first bearing for the seconddrive member; a first connector coupled to the first drive member fortransfer of torque therebetween, the first connector having a firstconnector face; a spherical bearing positioned in the first connectorfor receiving the first end of the second drive member for rotation ofthe second drive member about a second axis, the spherical bearing beingpositioned at the intersection of the first and second axes; a secondconnector having a second connector face, and being rotationallycoupleable to the first connector for transmission of torquetherebetween, wherein the second connector is coupleable to the seconddrive member for transfer of torque therebetween; and a compressiblespacer positioned between the first connector face and the secondconnector face, thereby permitting the first and second connector facesto be non-parallel to one another.